Hard Start Kit for Multiple Replacement Applications

ABSTRACT

A hard start capacitor replacement unit includes a capacitor container having a cover, a plurality of capacitors received within the container, each of said capacitors having a capacitance value, a common terminal mounted on the cover and electrically connected to a common terminal of each of said plurality of capacitors, a plurality of cover terminals mounted on the cover spaced apart from the common terminal and from each other, each cover terminal respectively electrically connected to one of the plurality of capacitors, a relay having contacts and being capable of opening and closing said contacts in response to a monitored condition of the motor, the relay having relay terminals, a fuse electrically connected to one of the relay terminals by a first wire wherein the fuse electrically disconnects the hard start capacitor replacement unit and the motor upon a failure, and a second wire electrically connecting one of the relay terminals and the motor, a third wire electrically connecting the common terminal and one of the relay terminals, a fourth wire electrically connecting one or more cover terminals to one of the relay terminals, wherein the contacts of the relay close to electrically connect one or more capacitors of the plurality of capacitors to the motor, and the contacts of the relay open to electrically disconnect the one or more capacitors of the plurality of capacitors from the motor.

CLAIM OF PRIORITY

This application claims the benefit of U.S. Patent Application Ser. Nos.63/182,540, filed Apr. 30, 2021, and 63/282,965, filed Nov. 24, 2021.The entire contents of the foregoing are hereby incorporated byreference.

TECHNICAL FIELD

The disclosure herein relates to a hard start capacitor replacement unitthat is adaptable in the field for replacing any one of a plurality ofmultiple hard start modules.

BACKGROUND

Single phase induction motors of the type commonly used with airconditioner and cooling equipment compressors generally require sometype of auxiliary start capacitor for starting the motor. A startcapacitor, also sometimes referred to as a “hard start capacitor,” isconnected for a short period of time to start the motor, and the startcapacitor is disconnected from the motor near or at the time the motorachieves its run speed. This time is generally on the order of 50-100milliseconds. The start capacitor can be wired in series with contactsfor disconnecting it. The contacts can be a part of a relay (e.g., apotential relay, a control relay, an electronic relay, etc.).

If the start capacitor or the relay controlling it fails, replacing thestart capacitor and control relay is needed, and this generally isaccomplished at the site of the motor. For air conditioners and othercooling equipment, this site could be a home, an office, a warehouse orfactory, store, or any other building. This complicates the task ofreplacing the start capacitor and its connecting relay, in that a widevariety of brands and sizes of air conditioning and cooling units are inuse, and these units use start capacitors having a variety ofcapacitances. Therefore, unless a repairman has a replacement hard startkit available with the correctly sized start capacitor, the repairmancannot complete repair without returning to a shop or parts distributorthat has an inventory of hard start capacitor replacement parts.

Having to return to a shop or parts distributor in order to obtain thenecessary materials to complete a repair is inefficient and timeconsuming and also delays the time that the customer's cooling systemcan be returned to operation.

Therefore, it would be advantageous if a repairman could carry one hardstart replacement unit that is adaptable to many air conditioning units,cooling units, or other equipment utilizing single phase motorsrequiring a start capacitor, so that the repairman could adapt the hardstart replacement unit to the requirements at hand and complete therepair in a timely manner.

SUMMARY

It is an advantage of the disclosure to provide a hard start capacitorreplacement unit adaptable to more than one motor.

It is an additional advantage of the disclosure to provide a hard startcapacitor replacement unit with selectable capacitance.

It is also an advantage of the disclosure to provide a hand startcapacitor replacement unit with circuit interruption protection.

It is a further advantage of the disclosure to provide a hard startcapacitor replacement unit that can be configured at a repair site toprovide a desired selected capacitance.

It is also an advantage of the disclosure to provide a hard startcapacitor replacement unit with at least four selectable capacitances.

It is another advantage of the disclosure to provide a hard startcapacitor replacement unit with selectable capacitance that mounts insubstantially the same space as an original start capacitor unit.

A hard start capacitor replacement unit is provided and has a capacitorcontainer with a cover. A plurality of capacitors are contained withinthe container, each of said capacitors having a capacitance value. Acommon terminal is provided on the cover and is electrically connectedto common terminals of each of the plurality of capacitors. A pluralityof cover terminals is also provided on the cover spaced apart from thecommon terminal and from each other, with each cover terminalrespectively electrically connected to one of the plurality ofcapacitors. A relay has contacts and is capable of opening and closingsaid contacts in response to a monitored condition of the motor. Therelay also has external relay terminals. A fuse is electricallyconnected to the relay by a wire. The fuse electrically disconnects thehard start capacitor replacement unit and the motor upon a failure. Asecond wire electrically connects another relay terminal and the motor.A third wire electrically connects the common terminal and a relayterminal. A fourth wire electrically connects one or more coverterminals of the hard start capacitor replacement unit to one of therelay terminals. The contacts of the relay close to electrically connectone or more capacitors to the motor, and the contacts of the relay opento electrically disconnect the one or more capacitors from the motor.

In another aspect, the relay is positioned external to the capacitorcontainer.

In another aspect, the fuse electrically disconnects the hard startcapacitor replacement unit from the motor upon a current exceeding athreshold for a predetermined period of time.

In additional aspects, the threshold is at least 4 amperes.

In some aspects, the threshold is at least 10 amperes.

In additional aspects, the predetermined period of time is five seconds.

In some aspects, the fuse electrically disconnects the hard startcapacitor replacement unit from the motor upon a failure of the relay.

In another aspect, the fuse electrically disconnects the hard startcapacitor replacement unit from the motor upon a current exceeding 10amperes for 5 seconds.

In another aspect, the fuse is electrically connected to a run capacitorof the motor.

In additional aspects, the run capacitor includes a booster terminal.

In some aspects, the fuse electrically disconnects the hard startcapacitor and the booster terminal of the run capacitor upon a failure.

In another aspect, a hard start capacitor replacement unit is providedand has a capacitor container with a cover. A plurality of capacitorsare contained within the container, each of said capacitors having acapacitance value. A common terminal is provided on the cover and iselectrically connected to common terminals of each of the plurality ofcapacitors. A plurality of cover terminals is also provided on the coverspaced apart from the common terminal and from each other, with eachcover terminal respectively electrically connected to one of theplurality of capacitors. A relay has contacts and is capable of openingand closing said contacts in response to a monitored condition of themotor. The relay also has external relay terminals. A fuse is mounted tothe relay and electrically connected to the relay. The fuse electricallydisconnects the hard start capacitor replacement unit and the motor upona failure. A first wire electrically connects another relay terminal andthe motor. A second wire electrically connects the common terminal and arelay terminal. A third wire electrically connects one or more coverterminals of the hard start capacitor replacement unit to one of therelay terminals. The contacts of the relay close to electrically connectone or more capacitors to the motor, and the contacts of the relay opento electrically disconnect the one or more capacitors from the motor.

In some aspects, the fuse electrically disconnects the hard startcapacitor from the motor upon a current exceeding a threshold for apredetermined period of time.

In another aspect, the threshold is at least four amperes.

In additional aspects, the threshold is at least ten amperes.

In some aspects, the predetermined period of time is five seconds.

In yet another aspect, the fuse is mounted on an external surface of therelay.

In another aspect, the fuse is electrically connected to a relayterminal external to the relay.

The foregoing and other advantages and features herein will, in part,appear in the following detailed description and claims, taken togetherwith the drawings.

DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of a hard start capacitor replacement unitshown connected to a schematic motor;

FIG. 2 is an exploded perspective view of the hard start capacitorreplacement unit of FIG. 1;

FIG. 3 is a sectional view of a capacitor, capacitor container and coverof the hard start capacitor replacement unit of FIG. 1;

FIG. 4 is a schematic circuit diagram of the hard start capacitorreplacement unit of FIG. 1, shown connected to a motor;

FIG. 5 is a top view of the cover and cover terminals of the hard startcapacitor replacement unit of FIG. 1, showing the capacitors connectedto provide a first capacitance value;

FIG. 6 is a top view of the cover and cover terminals of the hard startcapacitor replacement unit of FIG. 1, showing the capacitors connectedto provide a second capacitance value;

FIG. 7 is a top view of the cover and cover terminals of the hard startcapacitor replacement unit of FIG. 1, showing the capacitors connectedto provide a third capacitance value;

FIG. 8 is a top view of the cover and cover terminals of the hard startcapacitor replacement unit of FIG. 1 showing the capacitors connected toprovide a fourth capacitance value;

FIG. 9 is a schematic circuit diagram of another hard start capacitorreplacement unit, shown connected to a motor;

FIG. 10 is a sectional view of an example of a hard start capacitorreplacement unit and a magnet;

FIG. 11 is a sectional view of an example of a hard start capacitorreplacement unit and a magnet;

FIG. 12 shows an example of a hard start capacitor replacement unit andan externally mounted magnet;

FIG. 13 is a perspective view of a hard start capacitor replacement unitthat includes an externally connected relay;

FIG. 14A is a front view of an external relay with a fuse;

FIG. 14B is a back view of the external relay with the fuse;

FIG. 14C is a side view of the external relay with the fuse;

FIG. 14D is a side view of the external relay with the fuse;

FIG. 14E is a top view of the external relay with the fuse;

FIG. 14F is a bottom view of the external relay with the fuse;

FIG. 15 is a perspective view of a hard start capacitor replacement unitthat includes an externally connected relay with a fuse;

FIG. 16 is a sectional view of a run capacitor;

FIGS. 17A and 17B are schematic circuit diagrams of connections among arun capacitor, a start capacitor, and a compressor;

FIG. 18 is a schematic circuit diagram of connections among a runcapacitor, a start capacitor, and a compressor;

FIG. 18A is a schematic circuit diagram of other connections among a runcapacitor, a start capacitor, and a compressor;

FIG. 19 is a top view of a hard start capacitor replacement unitincluding an externally connected relay and a fuse;

FIG. 20 is a top view of a hard start capacitor replacement unitincluding an internal relay, the hard start capacitor replacement unitconnected to a fuse;

FIG. 21 is a view of the inside of a cover assembly of a hard startcapacitor replacement unit including an internally connected relay and afuse;

FIG. 22 is a top view of a hard start capacitor replacement with twocover terminals unit including an externally connected relay and a fuse;

FIGS. 23A and 23B are side views of wires, each wire including a fuseand connectors.

The same reference numerals refer to the same elements throughout thevarious Figures.

DETAILED DESCRIPTION

With reference to FIG. 1, a hard start capacitor replacement unit 10 isshown, including a cylindrical capacitor container 12 and a cylindricalcap 14 fitted onto the container 12 and extending therefrom. Withreference to FIG. 2, the cap 14 may be removed from the container 12, toexpose the cover 16 of the container, an electronic relay 18, and wiremeans 20 providing desired electrical connections for the hard startcapacitor replacement unit 10 to a motor 60.

The container 12 is preferably 2½ inches in diameter with a length of 5¾inches and has a plurality of capacitors therein; however otherdimensions can be employed. In the embodiment shown and with referenceto FIG. 3, four capacitors 22, 24, 26 and 28 are provided within thecontainer 12. Also in the embodiment shown, the capacitors 22, 24, 26and 28 are wound in a cylindrical capacitive element 30 having a commonelement terminal 32 at the bottom thereof and four capacitor terminals23, 25, 27 and 29 at the top thereof.

The capacitors of capacitive element 30 can be provided by metallizedfilm capacitors concentrically wound together as the cylindricalcapacitance element 30. The film is preferably polypropylene metallizedwith zinc and may be in a range of approximately 2-4 microns inthickness, for example. This is an advantageous film for severalreasons. First, start capacitors generally require a higher capacitancevalue than run capacitors, i.e., run capacitors generally have typicalcapacitance values in the range of about 15 to about 65 microfarads,whereas start capacitors may have typical capacitance values up to about300 microfarads. Such high start capacitance values have generally beenachieved with electrolytic capacitors because 300-microfarad capacitorswith typical film thicknesses would be bulky and require a largecontainer that may not fit into the space provided in an airconditioning unit or the like. However, with recognition that a startcapacitor is utilized for about one second or less as the motor starts,it does not have to be rated at high voltage over a long period of time.Therefore, a thin film may be used and the required capacitance isattained in a reasonably sized capacitive element. A further advantageis that the resultant metallized film capacitive element has stablecapacitance values over a relatively wide ambient temperature range, andalso has a long service life.

The container can be filled with a dielectric fluid 34 and the cover 16is provided with circuit interruption protection in the event thecapacitive element fails, such as shown in FIG. 3 and described in U.S.Pat. No. 7,203,053, the entirety of which is incorporated herein byreference. These are also advantages in fabricating the capacitors 22,24, 26 and 28 for the hard start capacitor replacement unit 10 frommetallized film.

In some arrangements, circuit interruption protection is provided by thewinding or windings, e.g., in the form of segmented film. For example, acircuit including segmented film can provide interruption protection toindividual segments of the circuit (e.g., by opening an electricalconnection) in the event of a capacitive failure. In some embodiments, acapacitive failure causes a reduction of capacitance as a dielectricfilm in the circuit segment fails. This occurs as very small linksbetween the segmented circuit separate as high current, created by,e.g., a capacitor or motor failure, crosses through the dielectric film,breaking the segmented circuit (e.g., creating an open circuit), whichcan prevent the damage from spreading throughout the circuit. The filmcan be, e.g., between about 4.0 μm and 4.8 μm in thickness, betweenabout 6.8 μm and 5.8 μm in thickness, or between about 1.0 μm and 25 μmin thickness.

In some implementations, the container is at least partially filledwith, e.g., solidified epoxy or resin (e.g., urethane, polyurethane,acrylic, cyanoacrylate, etc.) or a combination of materials. Forexample, the container can be halfway filled with epoxy, resin, or acombination of materials. In another example, the container can becompletely filled with epoxy, resin, or a combination of materials.

Although the capacitors may be provided in a cylindrical capacitiveelement 30 wound of metallized film, the capacitors 22, 24, 26, 28 maybe individual wound capacitors having respective ends electricallyconnected to form a common terminal. In some arrangements, capacitorsinclude multiple windings. In some arrangements, the capacitors may beprovided by a single winding. In some arrangements, common ends of thecapacitors are electrically connected. In some arrangements,capacitances are provided by connecting individual capacitors. In somearrangements, capacitances are provided by multiple windings which arevertically stacked on top of each other. Combinations of windings inseries or in parallel can be arranged to provide a capacitance value.Arrangements of capacitors with single or multiple windings aredescribed in U.S. Pat. No. 7,423,861, which is incorporated herein byreference in its entirety. For example, first and second dielectricfilms, each having a metalized layer on one side thereof, are wound incylindrical form on the mandrel with the non-metalized side of one filmbeing in contact with the metalized side of the other. Selected portionsof one or both of the metalized layers are removed in order to provide amultiple section capacitive element.

Element insulation barriers are inserted into the winding to separatethe capacitor sections, the element insulation barriers also assuming acylindrical configuration. Five element insulation barriers 30-34 areprovided to separate the six capacitor sections 20-25, with elementinsulation barrier 30 separating capacitor sections 20 and 21, elementinsulation barrier 31 separating capacitor sections 21 and 22, elementinsulation barrier 32 separating capacitor sections 22 and 23, elementinsulation barrier 33 separating capacitor sections 23 and 24, andelement insulation barrier 34 separating capacitor sections 24 and 25.

The individual wound capacitors can be connected in a variety of ways toprovide the desired capacitances. Some implementations includeconnections between multiple windings. For example, in severalimplementations, the individual wound capacitors can be connected inseries to provide the desired capacitances. In some implementations, theindividual wound capacitors can be connected in parallel to provide thedesired capacitances. In some implementations, individual woundcapacitors can be connected to each other in a mixture of series andparallel (e.g., some capacitors can be connected in series and some canbe connected in parallel). The capacitive element 30 may be providedwith more or less than five capacitors. The capacitors may also beprovided as two or more capacitive elements each having one or morecapacitors.

In the hard start capacitor replacement unit 10 shown and describedherein, the capacitors can have a range of values. For example,capacitor 22 connects to capacitor terminal 23 and can have a range ofvalues (e.g., a capacitance of 48 microfarads, 44 microfarads, 42microfarads, etc.). Capacitor 24 includes capacitor terminal 25 and canalso have a range of values (e.g., a capacitance of 48 microfarads, 44microfarads, 42 microfarads, etc.). Capacitor 26 includes capacitorterminal 27 and can have a range of value (e.g., a capacitance of 88microfarads, 84 microfarads, 82 microfarads, etc.) and capacitor 28includes capacitor terminal 29 and can have a range of values (e.g., acapacitance of 114 microfarads, 112 microfarads, 110 microfarads, etc.).In some instances, multiple capacitors have equivalent values. In someinstances, multiple capacitors have different values.

As perhaps best seen in FIGS. 5-8, the cover 16 includes a common coverterminal 40 in the center thereof, and includes capacitance valueterminals 42, 44, 46 and 48 spaced apart from the common cover terminal40 and from each other. The common cover terminal 40 is connected tocommon element terminal 32 of the capacitive element 30 and thereby toeach of the capacitors 22, 24, 26 and 28. The capacitance value coverterminal 42 is connected to the capacitor terminal 23 of capacitor 22and the capacitance value cover terminal 44 is connected to thecapacitor terminal 25 of capacitor 24. The capacitance value coverterminal 46 is connected to the capacitor terminal 27 of capacitor 26and the capacitance value cover terminal 48 is connected to thecapacitor terminal 29 of capacitor 28. Therefore, the capacitance valuesof the capacitors 22, 24, 26, 28 are respectively available for wireconnections at the corresponding capacitance value cover terminals 42,44, 46, 48 on the cover 16 of container 12.

A cover insulation barrier 50 is also mounted to the cover 16 to betterisolate the cover terminals. The cover insulation barrier 50 has acylindrical portion 52 surrounding the common cover terminal 40 and hasradial extending fins 54-58 that separate the other capacitance valuecover terminals. An extra fin is shown, which would insulate another oneor two capacitance value cover terminals if an additional one or twocapacitors were provided.

With reference to FIG. 4, a schematic diagram of the start capacitorreplacement unit 10 is shown. The electronic relay 18 has externalterminals that accept electrical connections (e.g., wire terminationclips) so that the external terminals can be connected, for example, tothe common cover terminal 40, and the capacitance value cover terminals42, 44, 46 and 48, as well as with start and run terminals 62 and 64 ofthe motor 60. External terminals T-1 and T-2 of electronic relay 18 areinternally connected with contacts 70 and 72, respectively, that may beconnected by a contact bar 74, as schematically shown. The electronicrelay 18 also includes an external terminal T-5. The electronic relay 18includes circuitry indicated at 76 that monitors the voltage and thedv/dt between terminals T-2 and T-5 and controls the opening and closingof the contacts 70 and 72 in response thereto. Terminals T-2 and T-5 areconnected to the start and run terminals 62 and 64 of compressor motor60 by wires 20, so that the electronic relay monitors the voltage acrossthe start and run windings. Terminal T-5 may also be connected betweenthe start and run windings of motor 60. When the contacts 70 and 72 areclosed, the electronic relay 18 connects the selected ones of thecapacitors 22, 24, 26 and 28 across the terminals 62 and 64 in parallelwith the run capacitor 66 to assist in starting the motor. A bleederresistor 78 discharges the capacitor(s) when contacts 70, 72 are open.The bleeder resistor 78 can have a range of suitable resistances (e.g.,about 8 kOhms to about 20 kOhms). A suitable electronic relay isavailable from Zhejiang Hongli Electric Co., Part No. HLR3800-6AM1D.

With reference to FIG. 9, the hard start capacitor replacement unit 10may also be used with a control or potential relay 90 as shown in theschematic. The relay contacts 92 and 94 are closed by contact bar 74 toconnect selected ones of capacitors 22, 24, 26, 28 across run terminals62, 64 of motor 60, and contacts 92, 94 are opened by coil 96 when themotor 60 starts. Bleeder resistor 98 is provided to bleed off thecapacitor charge when the contacts 92, 94 are open.

It will also be appreciated that although the capacitors of the hardstart unit 10 are shown connected across motor terminals 62, 64, thepurpose of this connection is to connect the capacitors of the startcapacitor in parallel with the motor run capacitor 66 of the motor 60,and any connection that accomplishes this is suitable.

Referring again to FIG. 4, the capacitors 22, 24, 26 and 28 areconnected as also shown in FIG. 8, in which a first wire 80 connects T-1of the electronic relay with the capacitance value cover terminal 48,which can provide 112 microfarads of capacitance value. Jumper wire 82between capacitance value cover terminals 48 and 46 can provide anadditional 88 microfarads of capacitance value into the circuit. Wire 88connects the common terminal 40 to terminal T-5 of the electronic relay18. Jumper wire 84 connecting capacitance value cover terminal 46 andcapacitance value cover terminal 44 can provide a further 48 microfaradsinto the circuit. Thus, in the configuration shown in FIGS. 4 and 6, atotal capacitance of 248 microfarads is provided to start the motor 60when the contacts of the electronic relay 18 are closed.

It will be appreciated that a variety of capacitance values may beselected by connecting various ones of the capacitance value coverterminals to each other. Some preferred connections are shown in FIGS.5-8. FIG. 5 shows connection of capacitor 28 by wire 80 at capacitancevalue cover terminal 48 (e.g., providing 112 microfarads), which issuitable for use where capacitance values in the range 108-130microfarads are desired for the motor start. FIG. 6 shows connection ofcapacitors 26 and 28 by jumper wire 82 at capacitor value coverterminals 46 and 48 providing, e.g., 200 microfarads of capacitancevalue, which is suitable for desired capacitance values in the range of189-227 microfarads. FIG. 7 shows all of the capacitors 22, 24, 26, 28connected into the circuit at capacitor value cover terminals 42, 44, 46and 48 by jumper wires 82, 84 and 86 to provide, e.g., a total 296microfarads, which is suitable for use in applications requiringcapacitance values in the range of 270-324 microfarads. FIG. 8 showsconnection of capacitors 28, 26 and 24 by jumper wires 82 and 84providing 248 microfarads, for use with applications requiringcapacitance values of 233-280 microfarads.

If desired, the total capacitance values connected into the circuit canbe further refined with possible capacitance values of, for example, 48microfarads, 88 microfarads, 96 microfarads, 136 microfarads, 160microfarads, 184 microfarads and 208 microfarads, being available inaddition to the 112 microfarads, 200 microfarads, 240 microfarads and296 microfarads configurations shown above. Lower values and highervalues are also possible.

Once the desired capacitance value is selected by placing appropriatejumper wires on the cover terminals, the cap 14 may be fitted over thecontainer 12, to surround the capacitor value cover terminals andelectronic relay 18. The hard start capacitor replacement unit 10 has asuitable size and shape to be accommodated in the space provided for theoriginal start capacitor, so the hard start replacement unit 10 isreadily accepted for mounting in existing equipment.

As a result of the foregoing, a repairman can carry the hard startcapacitor replacement unit 10 to repair site with confidence that afailed start capacitor unit can be replaced without need to return to ashop or parts distributor in order to complete the repair.

Another hard start capacitor replacement unit 1000 is illustrated inFIG. 10. The relay of this hard start capacitor replacement unit 1000 isnot shown. The hard start capacitor replacement unit 1000 may have thesame or similar external appearance and functionality as hard startcapacitor replacement unit 10, and may be adapted to replace any one ofa large number of capacitors with the hard start capacitor replacementunit 1000 connected to provide the same capacitance value or values of afailed capacitor.

The hard start capacitor replacement unit 1000 may include one or moremagnetic elements for assisting in mounting of the hard start capacitorreplacement unit 1000 (e.g., to an air conditioning system). In theillustrated example, a magnet 1002 is positioned toward a bottom end ofthe hard start capacitor replacement unit 1000. In particular, themagnet 1002 is positioned between a bottom wall 1004 of a case 1006(e.g., sometimes referred to as a container) of the hard start capacitorreplacement unit 1000 and a bottom cup 1008 of the hard start capacitorreplacement unit 1000 (e.g., beneath a center post 1010 of the bottomcup 1008). The magnet 1002 is configured to create magnetic attractionbetween the magnet 1002 and a magnetic attractable surface in proximityto the hard start capacitor replacement unit 1000. For example, themagnet 1002 may cause the bottom wall 1004 of the case 1006 to beattracted to a metallic surface of an air conditioning system, therebyimproving the integrity of a mounting between the hard start capacitorreplacement unit 1000 and the air conditioning system afterinstallation. The magnet 1002 may be designed such that the strength ofmagnetic attraction between the magnet 1002 and the air conditioningsystem is such that the magnet 1002 may remain firmly in place inresponse to possible vibration and/or other movement of the airconditioning system during operational use. In some implementations, thestrength of magnetic attraction between the magnet 1002 and the aircondition system is such that a user (e.g., a technician installing oruninstalling the hard start capacitor replacement unit 1000) can removethe hard start capacitor replacement unit 1000 from the surface of theair conditioning system without requiring excessive effort.

While the magnet 1002 is illustrated as being positioned interior to thecase 1006 of the hard start capacitor replacement unit 1000, in someimplementations, the magnet 1002 may be positioned outside of the case1006 on an exterior of the bottom wall 1004 of the case 1006. Forexample, the magnet 1002 may have a disk shape that is positionedoutside of the case 1006 at an outer surface of a base of the case 1006.

In some examples, the magnet 1002 may have a rectangular shape. Forexample, the magnet 1002 may be a rectangular strip that runs along thebottom wall 1004 of the case 1006 of the hard start capacitorreplacement unit 1000. In particular, the rectangular strip may have aparticular thickness, a first dimension that runs from the left side ofthe hard start capacitor replacement unit 1000 to the right side of thehard start capacitor replacement unit 1000 as illustrated in FIG. 10,and a second dimension that is perpendicular to the first dimension andsmaller than the first dimension. In some implementations, the magnet1002 may have a square shape (e.g., such that the first dimension isequal to or substantially equal to the second dimension). In someimplementations, the magnet 1002 may have a rod shape. In someimplementations, the magnet 1002 may have a circular shape (e.g., a diskshape) or a hollow circular shape (e.g., a ring shape). For example, insome implementations, the magnet 1002 may have dimensions equal to orsubstantially equal to the dimensions of a disk-shaped battery (e.g., awatch battery such as a CR2032 battery). In some implementations, themagnet 1002 is a disk-shape with a thickness of approximately 4 mm and adiameter of approximately 160 mm. In some implementations, the magnet1002 is a disk-shape with a thickness of approximately 4 mm and adiameter of approximately 40 mm. In some implementations, the magnet1002 is a disk-shape with a thickness of approximately 4.5-5 mm and adiameter of about 60 mm. In some implementations, the magnet 1002 is adisk-shape with a thickness of approximately 5 mm and a diameter ofabout 60 mm.

The particular shape and/or dimensions of the magnet 1002 may be chosento achieve the desired strength of magnetic attraction. For example, themagnet 1002 may be designed with a particular shape and/or largerdimensions and/or larger thicknesses to achieve a relatively higherstrength of magnetic attraction with a magnetic surface. In someimplementations, increased surface area of the magnet 1002 toward thebottom wall 1004 of the case 1006 of the hard start capacitorreplacement unit 1000 may increase the strength of magnetic attraction.

In some implementations, the magnet 1002 has a strength of approximately30-40 milliTeslas (mT) or a strength of approximately 65-75 mT. In someimplementations, the strength of magnetic attraction can be increased bystacking multiple magnets 1002 (e.g., on top of each other). In someimplementations, two stacked magnets 1002 can have a strength ofapproximately 70-80 mT, 60-80 mT, or 130-150 mT, although other rangesare also possible. In some implementations, the magnet 1002 may be aD40×4 ferrite ceramic magnet manufactured by Hangzhou Honesun MagnetCo., Ltd.

In some implementations, the magnet 1002 may be magnetized using one ormore of a plurality of techniques. For example, in some implementations,the magnet 1002 may be magnetized such that a north and a south pole ofthe magnet 1002 is located at a particular position of the magnet 1002.For example, the techniques for magnetizing the magnet 1002 may causethe north and/or south pole to be located at various thicknesses of themagnet 1002, various axial positions of the magnet 1002, variousdiametric positions of the magnet 1002, and/or various radial positionsof the magnet 1002. In some implementations, the magnet 1002 may be amulti-pole magnet.

In some implementations, the magnet 1002 is a permanent magnet that ismade from a material that is magnetized and creates its own persistentmagnetic field. For example, the magnet 1002 may be made from aferromagnetic material that can be magnetized, such as iron, nickel,cobalt, and/or an alloy of rare-earth metals, among others. In someimplementations, the magnet 1002 is a ferrite and/or ceramic magnet. Insome implementations, the magnet 1002 may include one or more of ferricoxide, iron oxide, barium, barium carbonate, strontium, and/or strontiumcarbonate. The magnet 1002 may include one or more magnetically “hard”materials (e.g., materials that tend to stay magnetized). Alternativelyor additionally, the magnet 1002 may include one or more magnetically“soft” materials.

In some implementations, the magnet 1002 may be a rare-earth magnet. Arare-earth magnet is typically a relatively strong permanent magnet thatis made from one or more alloys of rare-earth elements. Example ofrare-earth elements that can be used in a rare-earth magnet includeelements in the lanthanide series, scandium, and yttrium, although otherelements may also or alternatively be used. In some implementations, therare-earth magnet may produce a magnetic field of greater than 1.0 T(teslas). In some implementations, the rare-earth magnet may include oneor both of samarium-cobalt and neodymium.

In some implementations, the magnet 1002 may be made from one or moreceramic compounds (e.g., ferrite) that can be produced by combining ironoxide and one or more metallic elements. In some implementations, suchceramic compounds may be electrically nonconductive. The use of suchceramic compounds for the magnet 1002 may eliminate the inclusion ofelectrically conductive elements in the hard start capacitor replacementunit 1000 that may otherwise affect the operation of the hard startcapacitor replacement unit 1000.

In some implementations, the magnet 1002 may have a grade thatcorresponds to a particular standard (e.g., a National and/orInternational standard). In some implementations, the grade of themagnet 1002 corresponds to the Chinese ferrite magnet nomenclaturesystem. For example, in some implementations, the magnet 1002 is gradeY10T, Y25, Y30, Y33, Y35, Y30BH, or Y33BH, although other grades arealso possible. In some implementations, the grade corresponds to aworking temperature of 250° C. In some implementations, the grade of themagnet 1002 corresponds to a Feroba, an American (e.g., “C”), or aEuropean (e.g., “HF”) grading standard.

In some implementations, the magnet 1002 may be an electromagnet thatproduces a magnetic field by introducing an electric current. In someimplementations, the electromagnet may include a magnetic core and awire (e.g., an insulated wire) wound into a coil around the magneticcore. The magnetic core may be made from a ferromagnetic or aferrimagnetic material such as iron or steel. The magnetic core may bemade from a “soft” magnetic material (e.g., a magnetic material that canallow magnetic domains in the material to align upon introduction of thecurrent through the coil).

By using an electromagnet as the magnet 1002, the strength of magneticattraction can be turned on and off and/or customized according to thecurrent passed through the coil. For example, current can be appliedthrough the coil to cause the electromagnet to generate a magneticfield, and the current can be removed from the coil to cause theelectromagnetic to cease generating the magnetic field. In someimplementations, the strength of the magnetic field (and, e.g., thestrength of magnetic attraction created by the electromagnet) can beadjusted based on the magnitude of electrical current passed through thecoil. For example, relatively higher magnitudes of electrical currentcorrespond to higher magnetic field strengths and therefore higherstrengths of magnetic attraction (e.g., with a magnetic surface), andrelatively lower magnitudes of electrical current correspond to lowermagnetic field strengths and therefore lower strength of magneticattraction.

In some implementations, the particular material used for the core ofthe electromagnet and/or the dimensions of the core may be chosen toachieve the desired strength of magnetic attraction. The core may bemade from a material such as one or both of iron and steel. In someimplementations, the dimensions of the coil and/or the number of turnsof the coil may also be chosen to achieve the desired strength ofmagnetic attraction.

In some implementations, the current that is provided through the coilmay be provided by a connection with one or more of the capacitancevalue terminals and the common cover terminal 1012 of the hard startcapacitor replacement unit 1000. For example, a conductor (e.g., a wire)may be used to connect one or more of the capacitance value terminals toa first end of the coil and a conductor may be used to connect anotherone of the capacitance value terminals or the common cover terminal 1012to a second end of the coil. In this way, the current that otherwiseruns through the electrical components of the hard start capacitorreplacement unit 1000 can also be used to power the electromagnetic,thereby causing the electromagnet to generate a magnetic field.

In some implementations, the hard start capacitor replacement unit 1000may include one or more different and/or additional electricalcomponents that can be used by the electromagnet to generate themagnetic field. For example, the hard start capacitor replacement unit1000 may include a separate capacitor that is configured to store acharge to be used to subsequently apply current through the coil of theelectromagnet. In this way, the electromagnet may have a separate powersource that can be used when generation of a magnetic field is desired.

In some implementations, the hard start capacitor replacement unit 1000may include a switch that can be toggled by a user (e.g., a technicianor an operator of the hard start capacitor replacement unit 1000) tocause the electromagnet to generate or cease generating the magneticfield. The switch may cause an electrical connection in the coil to betemporarily broken and restored. In some implementations (e.g.,implementations in which the coil is connected to one or more of thecapacitance value terminals and/or the common cover terminal 1012), theswitch may cause the conductor that connects the coil to one or more ofthe capacitance value terminals and/or the conductor that connects thecoil to the common cover terminal 1012 to be temporarily broken andrestored, such that the magnetic field generated by the electromagnetcan be toggled on and off. In this way, the user can toggle the magneticfield on when mounting of the hard start capacitor replacement unit 1000is desired (e.g., at the time of installation) and toggle the magneticfield off when mounting of the hard start capacitor replacement unit1000 is not desired (e.g., when the hard start capacitor replacementunit 1000 is not in use and/or being stored) or when magnetic attractionis not desired (e.g., when mounting the hard start capacitor replacementunit 1000 at a location that does not include a magnetic surface).

In some implementations, the capacitive element of the hard startcapacitor replacement unit 1000 and/or the capacitors of the hard startcapacitor replacement unit 1000 may be used to store the charge that isprovided to the coil to cause the magnetic field to be generated. Forexample, the capacitive element 1014 and/or one or more of thecapacitors 1016, 1018, 1020, 1022 may be configured to store a chargethat is subsequently provided to the coil of the electromagnetic. Inthis way, electrical charge that is otherwise stored by the hard startcapacitor replacement unit 1000 during typical use can also be used topower the electromagnet.

While the hard start capacitor replacement unit 1000 shown in theillustrated example includes one magnet 1002, additional magnets mayalso be provided. For example, a plurality of magnets may be positionedbetween the bottom wall 1004 of the case 1006 of the hard startcapacitor replacement unit 1000 and the bottom cup 1008 of the hardstart capacitor replacement unit 1000. The plurality of magnets may havedimensions that are relatively smaller than dimensions that may bechosen for implementations in which only a single magnet 1002 is used.The plurality of magnets may have dimensions substantially similar todimensions of a watch battery, such as a CR2032 battery. The pluralityof magnets may be positioned at various locations at the bottom wall1004 of the case 1006. For example, the plurality of magnets may bearranged in a ring around a perimeter of the bottom wall 1004 such thatthe plurality of magnets are spaced approximately equidistant from oneanother. In some implementations, the plurality of magnets may bearranged in groups of two, three, etc. magnets 1002. Any number ofmagnets 1002 may be provided to achieve the desired strength of magneticattraction.

In some implementations, the hard start capacitor replacement unit 1000includes two magnets (e.g., similar to magnet 1002) positioned betweenthe bottom wall 1004 of the case 1006 and the bottom cup 1008. In someimplementations, the two magnets are each circular shape (e.g., diskshaped). The two magnets may have a stacked configuration such that afirst disk shaped magnet is stacked on top of a second disk shapedmagnet. In some implementations, the two magnets may have a combinedstrength of approximately 70-80 mT, 60-80 mT, or 130-150 mT, althoughother ranges are also possible. The two magnets may have the same ordifferent diameters. In some implementations, the two magnets may bepositioned at a location that is misaligned with a center of the bottomwall 1004 of the case 1006. For example, the center of the magnets maybe misaligned with the center of the bottom wall 1004 of the case 1006such that the magnets are positioned proximate to a side wall 1024 ofthe case. In some implementations, the center of the magnets may bealigned with the center of the bottom wall 1004 of the case 1006. Insome implementations, the centers of the two magnets may be misalignedrelative to each other. In other words, a center of one of the magnetsmay be misaligned with a center of the other magnet.

Another hard start capacitor replacement unit 1100 is illustrated inFIG. 11. The hard start capacitor replacement unit 1100 may have thesame or similar external appearance and functionality as hard startcapacitor replacement unit 10 and 1000, and may be adapted to replaceany one of a large number of capacitors with the hard start capacitorreplacement unit 1100 connected to provide the same capacitance value orvalues of a failed capacitor.

The hard start capacitor replacement unit 1100 may include one or moremagnets for assisting in mounting of the hard start capacitorreplacement unit 1100 (e.g., to an air conditioning system). In theillustrated example, a magnet 1102 is positioned inside a side wall 1104of a case 1106 (e.g., sometimes referred to as a container) of the hardstart capacitor replacement unit 1100. The magnet 1102 is configured tocreate magnetic attraction between the magnet 1102 and a magneticsurface in proximity to the hard start capacitor replacement unit 1100.For example, the magnet 1102 may cause the side wall 1104 of the case1106 to be attracted to a metallic surface of an air conditioningsystem, thereby improving the integrity of a mounting between the hardstart capacitor replacement unit 1100 and the air conditioning systemafter installation. The magnet 1102 may be designed such that thestrength of magnetic attraction between the magnet 1102 and the airconditioning system is such that the magnet 1102 may remain firmly inplace in response to possible vibration and/or other movement of the airconditioning system during operational use. In some implementations, thestrength of magnetic attraction between the magnet 1102 and the aircondition system is such that a user (e.g., a technician installing oruninstalling the hard start capacitor replacement unit 1100) can removethe hard start capacitor replacement unit 1100 from the surface of theair conditioning system without requiring excessive effort.

In some examples, the magnet 1102 may have a rectangular shape. Forexample, the magnet 1102 may be a rectangular strip that runs from topto bottom along the side wall 1104 of the case 1106 of the hard startcapacitor replacement unit 1100. In particular, the rectangular stripmay have a particular thickness, a first dimension that runs from thetop end of the hard start capacitor replacement unit 1100 to the bottomend of the hard start capacitor replacement unit 1100, and a seconddimension that is perpendicular to the first dimension and smaller thanthe first dimension. In some implementations, the magnet 1102 may have asquare shape (e.g., such that the first dimension is equal to orsubstantially equal to the second dimension). In some implementations,the magnet 1102 may have a rod shape. In some implementations, themagnet 1102 may have a circular shape (e.g., a disk shape) or a hollowcircular shape (e.g., a ring shape). For example, in someimplementations, the magnet 1102 may have dimensions equal to orsubstantially equal to the dimensions of a disk-shaped battery (e.g., awatch battery such as a CR2032 battery). In some implementations, othershapes, a combination of shapes, etc. may be employed; for example,various types of curves may be incorporated into one or more magneticstrips (e.g., elongated oval shaped strips). Patterns of magneticmaterial may used; for example two crossed magnetic strips, a pattern ofcrosses, circles, etc. may be attached, incorporated into the bottomwall, side wall 1104, etc. of the hard start capacitor replacement unit1100.

In some implementations, the magnet 1102 may have a curved shape thatmatches or substantially matches a curve of the case 1106 of the hardstart capacitor replacement unit 1100. For example, the magnet 1102 mayhave a curve that allows the magnet 1102 to make continuous contact withthe side wall 1104 of the case 1106 of the hard start capacitorreplacement unit 1100. In some implementations, the magnet 1102 may havedimensions of approximately 1 inch×1 inch and a thickness of about 1/10of an inch. Such a magnet 1102 may be curved such that the magnet 1102is configured to interface with an inner wall of the case 1106 of thehard start capacitor replacement unit 1100 (e.g., interior to the case1106).

As described in more detail below, in some implementations, the magnet1102 (e.g., the curved magnet) may be positioned exterior to the case1106 of the hard start capacitor replacement unit 1100. In someimplementations, a first surface of the magnet 1102 may be curved suchthat the first surface of the magnet 1102 interfaces with an exteriorwall of the case 1106 of the hard start capacitor replacement unit 1100,and a second surface opposite of the first surface may have asubstantially flat shape that is configured to interface with a flatsurface of a separate object (e.g., a surface or wall of an airconditioning system). In some implementations, multiple curved magnets1102 may be provided in one or more of the configurations describedherein (e.g., including multiple curved magnets, a curved and anon-curved magnet, etc.).

In some implementations, the magnet 1102 may run along (e.g., makecontinuous contact) with the full perimeter of the side wall 1104 of thecase 1106. That is, the magnet 1102 may have a sleeve shape with adiameter that is slightly less than a diameter of the hard startcapacitor replacement unit 1100. In this way, substantially all of theside wall 1104 of the case 1106 of the hard start capacitor replacementunit 1100 may be magnetic such that the user can affix any portion ofthe side wall 1104 of the hard start capacitor replacement unit 1100 toa magnetic surface (e.g., without needing to rotate the hard startcapacitor replacement unit 1100 to find a surface that is in line withthe magnet 1102, as may be the case in implementations in which a magnet1102 having a strip shape is used).

The particular shape and/or dimensions of the magnet 1102 may be chosento achieve the desired strength of magnetic attraction. For example, themagnet 1102 may be designed with a particular shape and/or largerdimensions and/or larger thicknesses to achieve a relatively higherstrength of magnetic attraction with a magnetic surface. In someimplementations, increased surface area of the magnet 1102 toward theside wall 1104 of the case 1106 of the hard start capacitor replacementunit 1100 may increase the strength of magnetic attraction.

In some implementations, the magnet 1102 has a strength of approximately30-40 milliTeslas (mT) or a strength of approximately 65-75 mT. In someimplementations, the strength of magnetic attraction can be increased bystacking multiple magnets 1102 (e.g., one beside the other). In someimplementations, two stacked magnets 1102 can have a strength ofapproximately 70-80 mT, 60-80 mT, or 130-150 mT, although other rangesare also possible. In some implementations, the magnet 1102 may be aD40×4 ferrite ceramic magnet manufactured by Hangzhou Honesun MagnetCo., Ltd.

In some implementations, the magnet 1102 may be magnetized using one ormore of a plurality of techniques. For example, in some implementations,the magnet 1102 may be magnetized such that a north and a south pole ofthe magnet 1102 is located at a particular position of the magnet 1102.For example, the techniques for magnetizing the magnet 1102 may causethe north and/or south pole to be located at various thicknesses of themagnet 1102, etc. In some implementations, the magnet 1102 may be amulti-pole magnet.

In some implementations, the magnet 1102 is a permanent magnet that ismade from a material that is magnetized and creates its own persistentmagnetic field. For example, the magnet 1102 may be made from aferromagnetic material that can be magnetized, such as iron, nickel,cobalt, and/or an alloy of rare-earth metals, among others. In someimplementations, the magnet 1102 is a ferrite and/or ceramic magnet. Insome implementations, the magnet 1102 may include one or more of ferricoxide, iron oxide, barium, barium carbonate, strontium, and/or strontiumcarbonate. The magnet 1102 may include one or more magnetically “hard”materials (e.g., materials that tend to stay magnetized). Alternativelyor additionally, the magnet 1102 may include one or more magnetically“soft” materials.

In some implementations, the magnet 1102 may be a rare-earth magnet. Arare-earth magnet is typically a relatively strong permanent magnet thatis made from one or more alloys of rare-earth elements. Example ofrare-earth elements that can be used in a rare-earth magnet includeelements in the lanthanide series, scandium, and yttrium, although otherelements may also or alternatively be used. In some implementations, therare-earth magnet may produce a magnetic field of greater than 1.0 T. Insome implementations, the rare-earth magnet may include one or both ofsamarium-cobalt and neodymium.

In some implementations, the magnet 1102 may be made from one or moreceramic compounds (e.g., ferrite) that can be produced by combining ironoxide and one or more metallic elements. In some implementations, suchceramic compounds may be electrically nonconductive. The use of suchceramic compounds for the magnet 1102 may eliminate the inclusion ofelectrically conductive elements in the hard start capacitor replacementunit 1100 that may otherwise affect the operation of the hard startcapacitor replacement unit 1100.

In some implementations, the magnet 1102 may have a grade thatcorresponds to a particular standard (e.g., a National and/orInternational standard). In some implementations, the grade of themagnet 1102 corresponds to the Chinese ferrite magnet nomenclaturesystem. For example, in some implementations, the magnet 1102 is gradeY10T, Y25, Y30, Y33, Y35, Y30BH, or Y33BH, although other grades arealso possible. In some implementations, the grade corresponds to aworking temperature of 250° C. In some implementations, the grade of themagnet 1102 corresponds to a Feroba, an American (e.g., “C”), or aEuropean (e.g., “HF”) grading standard.

While the hard start capacitor replacement unit 1100 shown in theillustrated example includes one magnet 1102, additional magnets mayalso be provided. For example, a plurality of magnets may be positionedproximate to the side wall 1104 of the case 1106 of the hard startcapacitor replacement unit 1100. The plurality of magnets may havedimensions that are relatively smaller than dimensions that may bechosen for implementations in which only a single magnet 1102 is used.The plurality of magnets may have dimensions substantially similar todimensions of a watch battery, such as a CR2032 battery. The pluralityof magnets may be positioned at various locations proximate to the sidewall 1104 of the case 1106. For example, the plurality of magnets may bearranged in a ring around a perimeter of the side wall 1104 such thatthe plurality of magnets are spaced approximately equidistant from oneanother. In some implementations, the plurality of magnets may bearranged in groups of two, three, etc. magnets. Any number of magnets1102 may be provided to achieve the desired strength of magneticattraction.

Like the magnet 1002 described above with respect to FIG. 10, the magnet1102 illustrated in FIG. 11 can also be an electromagnet that includes acore and a coil wrapped around the core, in which the materials,dimensions, configuration, and/or operating characteristics of theelectromagnet can be chosen to achieve the desired strength of magneticattraction.

In some implementations, the hard start capacitor replacement units1000, 1100 may be configured to accept the magnet 1002, 1102 aftermanufacture of the hard start capacitor replacement unit 1000, 1100. Forexample, the hard start capacitor replacement unit 1000, 1100 mayinclude one or more movable surfaces (e.g., doors or compartments) thatcan be opened by the user such that the user can place the magnet 1002,1102 inside the hard start capacitor replacement unit 1000, 1100. Inthis way, the user can add and/or remove the magnet 1002, 1102 ifmagnetic attraction is desired or on longer desired. Further, the usercan add additional magnets or remove magnets if a lesser strength ofmagnetic attraction is desired. For example, if a surface to which thehard start capacitor replacement unit 1000, 1100 is mounted is highlymagnetic, the strength of magnetic attraction provided by theconfiguration of the magnets 1002, 1102 may be excessive. As such, theuser can remove one or more of the magnets 1002, 1102 from the hardstart capacitor replacement unit 1000, 1100 until the desired strengthof magnetic attraction is achieved. On the other hand, if a surface towhich the hard start capacitor replacement unit 1000, 1100 is mounted isrelatively non-magnetic, the strength of magnetic attraction provided bythe configuration of the magnets 1002, 1102 may be too low. As such, theuser can add one or more additional magnets to the hard start capacitorreplacement unit 1000, 1100 until the desired strength of magneticattraction is achieved.

In some implementations, a bottom end of the hard start capacitorreplacement unit 1000 (e.g., an area proximate to and including thebottom wall 1004 of the case 1006) may be removable from the rest of thecase 1006 of the hard start capacitor replacement unit 1000. In someimplementations, the bottom end of the hard start capacitor replacementunit 1000 may be attached by threading such that the bottom end of thehard start capacitor replacement unit 1000 may be removed by twistingthe bottom end of the hard start capacitor replacement unit 1000 awayfrom the rest of the case 1006. Removing the bottom end of the hardstart capacitor replacement unit 1000 may reveal a compartment withinwhich the magnet 1002 (and, e.g., additional magnets) can be placedand/or removed. In some implementations, the side wall 1104 of the case1106 of the hard start capacitor replacement unit 1100 may include aslidable and/or otherwise openable door that reveals a compartment ofthe hard start capacitor replacement unit 1100 within which the magnet1102 (and, e.g., additional magnets) can be placed and/or removed.

In some implementations, the case 1006, 1106 of the hard start capacitorreplacement unit 1000, 1100 may be made from a magnetic material (e.g.,a metallic material). The magnet 1002, 1102 may be held in place atleast in part by magnetic attraction between the magnet 1002, 1102 andthe case 1006, 1106. For example, the magnet 1002 may be magneticallyattracted to the bottom wall 1004 of the case 1006 of the hard startcapacitor replacement unit 1000, and the magnet 1102 may be magneticallyattracted to the side wall 1104 of the case 1106 of the hard startcapacitor replacement unit 1100. In some implementations, the case 1006,1106 may be made from a non-magnetic material such as a plasticmaterial. In such implementations, one or more other mechanisms ortechniques may be used to fix the magnet 1002, 1102 in place, asdescribed below.

In some implementations, the magnet 1002, 1102 may be affixed to asurface of the hard start capacitor replacement unit 1000, 1100 by oneor more mounting mechanisms. For example, one or more brackets may beused to affix the magnet 1002, 1102 to an interior and/or an exterior ofthe case 1006, 1106. In some implementations, one or more brackets maybe used to affix the magnet 1002 to the bottom wall 1004 of the case1006. In some implementations, a bracket may be positioned around asurface of the magnet 1002, and one or more fasteners may be used toaffix the bracket against the bottom wall 1004 of the case 1006.Similarly, one or more brackets may be used to affix the magnet 1102 tothe side wall 1104 of the case 1106. In some implementations, a bracketmay be positioned around a surface of the magnet 1102, and one or morefasteners may be used to affix the bracket against the side wall 1104 ofthe case 1106. In some implementations, an adhesive may be used to affixthe magnet 1002, 1102 to the bottom wall 1004 of the case 1006 and/orthe bottom cup 1008 and the side wall 1104 of the case 1106. In someimplementations, the magnet 1002, 1102 may be held sufficiently in placeby being wedged between the bottom wall 1004 of the case 1006 and thebottom cup 1008, or by being wedged between the side wall 1104 of thecase 1106 and other components of the hard start capacitor replacementunit 1100. In some implementations, magnetic attraction between themagnet 1002, 1102 and other components of the hard start capacitorreplacement unit 1000, 1100 (e.g., the case 1006, 1106) may assist inholding the magnet 1002, 1102 in place.

In some implementations, the magnet 1002, 1102 may be held in place atleast in part by an epoxy. For example, once the magnet 1002, 1102 ispositioned at its desired position within the case 1006, 1106 of thehard start capacitor replacement unit 1000, 1100, an epoxy can beintroduced in proximity to the magnet 1002, 1102. Upon curing, the epoxycan provide sufficient strength for holding the magnet 1002, 1102 in itsdesired mounting location.

In some implementations, a cutout (e.g., a recess) may be provided inwhich the magnet 1002, 1102 can be seated (e.g., to assist in holdingthe magnet 1002, 1102 in place at its desired mounting location). Thecutout may be provided in the case 1006, 1106 of the hard startcapacitor replacement unit 1000, 1100 and/or in the bottom cup 1008 ofthe hard start capacitor replacement unit 1000. The cutout may provide aridge that surrounds a perimeter of the magnet 1002, 1102 to keep themagnet 1002, 1102 in place. In this way, the magnet 1002, 1102 isprevented from sliding to other locations within the case 1006, 1106 ofthe hard start capacitor replacement unit 1000, 1100.

While the magnets 1002, 1102 have been illustrated as being positionedwithin the case 1006, 1106 of the hard start capacitor replacement unit1000, 1100, in some implementations, the magnet 1002, 1102 may bemounted to an exterior of the case 1006, 1106. For example, in someimplementations, the magnet 1002 may be mounted to a bottom surface ofthe bottom wall 1004 of the case 1006 of the hard start capacitorreplacement unit 1000. The magnet 1002 may have a shape thatsubstantially matches the shape of the bottom surface of the bottom wall1004. In this way, when the hard start capacitor replacement unit 1000is mounted to a magnetic object (e.g., an air conditioning system), thehard start capacitor replacement unit 1000 can be positioned flush withthe surface of the object. Similarly, in some implementations, themagnet 1102 may be mounted to an outside surface of the side wall 1104of the case 1106 of the hard start capacitor replacement unit 1100. Insome examples, the magnet 1102 may be wrapped around or substantiallyaround the outside surface of the side wall 1104 of the case 1106 suchthat substantially all outside surfaces of the case 1106 are magnetic.The magnet 1002, 1102 may be mounted using one or more mountingmechanisms, an adhesive, an epoxy, one or more fasteners, etc. In someimplementations, the magnet 1002, 1102 may be a magnetic film that isapplied to a portion of the case 1006, 1106 of the hard start capacitorreplacement unit 1000, 1100. For example, the magnet 1002, 1102 may be amagnetic film applied to the exterior of the case 1006, 1106.

In some implementations, the magnet 1002, 1102 may have a thickness ofapproximately 4 mm. For example, in implementations in which the magnet1002 is mounted to the bottom surface of the bottom wall 1004 of thecase 1006 of the hard start capacitor replacement unit 1000, a width ofapproximately 4 mm for the magnet 1002 may provide sufficient strengthof magnetic attraction without making the hard start capacitorreplacement unit 1000 unwieldy (e.g., by adding excessive height to thehard start capacitor replacement unit 1000). Therefore, the hard startcapacitor replacement unit 1000 does not take up excessive volume at itsmounting location (e.g., at or within an air conditioning system).

In some implementations, one or more portions of the case 1006, 1106 ofthe hard start capacitor replacement unit 1000, 1100 are themselvesmagnetic, and/or the bottom cup 1008 is magnetic. For example, the hardstart capacitor replacement unit 1000, 1100 may be designed such thatthe case 1006, 1106 is made from a magnetic material. In this way, thehard start capacitor replacement unit 1000, 1100 can be mounted in avariety of configurations as required for the particular application.For example, the bottom wall 1004 of the case 1006 of the hard startcapacitor replacement unit 1000 and/or the bottom cup 1008 of the hardstart capacitor replacement unit 1000 may be made from a magneticmaterial such that the bottom wall 1004 of the hard start capacitorreplacement unit 1000 can be magnetically attracted to a magneticobject, and/or the side wall 1104 of the case 1106 of the hard startcapacitor replacement unit 1100 may be made from a magnetic materialsuch that the side wall 1104 of the hard start capacitor replacementunit 1100 may be magnetically attracted to a magnetic object.

While the magnets 1002, 1102 have been illustrated and described asbelonging to different hard start capacitor replacement unit 1000, 1100,in some implementations, the magnet 1002 of FIG. 10 and/or the magnet1102 of FIG. 11 may be incorporated into other hard start capacitorreplacement units described herein. For example, in someimplementations, the magnet 1102 may also be incorporated into the hardstart capacitor replacement unit 1000 (e.g., instead of or in additionto the magnet 1002), and vice versa. In some implementations, one orboth of the magnet 1002 and the magnet 1102 may be incorporated into thehard start capacitor replacement unit 10, 1000, 1100.

While many implementations have been described above (e.g., such as theimplementations described with respect to FIGS. 10 and 11), otherimplementations are also possible. In some implementations, the hardstart capacitor replacement units described herein (e.g., the hard startcapacitor replacement unit 10, 1000, and/or 1100) may include multiplestacked magnets toward the bottom of the hard start capacitorreplacement unit (e.g., similar to the hard start capacitor replacementunit 1000 of FIG. 10, and as described above, between the bottom wall1004 of the case 1006 and the bottom cup 1008). For example, two magnetshaving a circular shape (e.g. disk shape) may be stacked on top of eachother such that the centers of the two magnets are in alignment. In someimplementations, the two magnets may be made from one or more ceramiccompounds (e.g., ferrite), for example, which can be produced bycombining iron oxide and one or more metallic elements.

In some implementations (e.g., in addition to implementations thatinclude the two stacked magnets described above), multiple magnets maybe provided at the side wall of the hard start capacitor replacementunit (e.g., the side wall 1024, 1104 of the hard start capacitorreplacement unit 1000, 1100). For example, two magnets may be providedinside the side wall 1024, 1104 of the hard start capacitor replacementunit 1000, 1100. The two magnets may have a curved shape (e.g., asdescribed above). In some implementations, each of the curved magnetsmay be configured to interface with an inner wall of the case 1006,1106. In some implementations, the curved magnets may have dimensions ofapproximately 1 inch×1 inch and a thickness of approximately 1/10 of aninch. In some implementations, the two curved magnets are stackedvertically. For example, a first curved magnet may be provided at afirst height between the side wall 1024, 1104 of the hard startcapacitor replacement unit 1000, 1100 and the capacitive element 1014,1110, and a second curved magnet may be provided at a second height(e.g., above or below the first height) between the side wall 1024, 1104of the hard start capacitor replacement unit 1000, 1100 and thecapacitive element 1014, 1110. In some implementations, each of thecurved magnets may run around a full circumference of the side wall1024, 1104 of the hard start capacitor replacement unit 1000, 1100(e.g., such that the magnets have a ring or sleeve shape). In someimplementations, one of the magnets may run around a full circumferencewhile the other magnet runs around less than an entirety (e.g., aportion) of the circumference. In yet additional implementations, bothof the magnets may run around less than an entire circumference (e.g., aportion of the circumference of the side wall 1024, 1104). In someimplementations, the two curved magnets are positioned at the samevertical height along the length of the side wall 1024, 1104. In suchimplementations, the two curved magnets may each run less than theentire circumference of the side wall 1024, 1104. In someimplementations, one or both of the two curved magnets may be arare-earth magnet that includes neodymium.

In some implementations, one or both of the magnets placed inside theside wall 1024, 1104 may be positioned between an inside surface of theside wall 1024, 1104 and a portion of the bottom cup 1008, 1108. Forexample, one or both of the curved magnets may be positioned between theside wall 1024, 1104 and an up-turned skirt that embraces the capacitiveelement 1014, 1110 and spaces the capacitive element 1014, 1110 from theside wall 1024, 1104 of the case 1006, 1106. In some implementations,the up-turned skirt may run further up the side wall 1024, 1104 anadditional length than what is illustrated in the figures (e.g., inFIGS. 10 and 11). The multiple curved magnets may be stacked verticallyor located at the same vertical height in a manner similar to thatdescribed above.

In some implementations, a liner may be positioned between the twocurved magnets and the capacitive element 30. For example, inimplementations in which the curved magnets are not positioned betweenthe side wall 1024, 1104 and the up-turned skirt, a liner may be appliedover one or both of the curved magnets to separate the curved magnetsfrom the capacitive element 1014, 1110. The liner may include anonconductive material or any other material suitable for separating themagnets from the capacitive element 1014, 1110 (e.g., for minimizingeffects of the magnet on the performance of the capacitive element 1014,1110 and/or other components). In some implementations, the liner is aplastic adhesive material that can be applied over a surface of one orboth of the curved magnets to separate the curved magnets from othercomponents of the hard start capacitor replacement unit 1000, 1100. Insome implementations, the liner can assist in holding the one or both ofthe curved magnets in place at the side wall 1024, 1104 of the hardstart capacitor replacement unit 1000, 1100.

In some implementations, one or both of the two curved magnets may bepositioned between the bottom cup 1008, 1108 of the hard start capacitorreplacement unit 1000, 1100 and the bottom wall 1004, 1164 of the hardstart capacitor replacement unit 1000, 1100. For example, one or both ofthe curved magnets may be placed in a position between the bottom cup1008 and the bottom wall 1004 of the hard start capacitor replacementunit 1000 shown in FIG. 10. The curved magnets may be placed instead ofor in addition to the magnet 1002 of FIG. 10. The one or both of thecurved magnets may be positioned in one or more of the configurationsdescribed in the preceding paragraphs. For example, the two curvedmagnets may be stacked vertically (e.g., one on top of the other, withthe two curved magnets optionally making contact with one another) orthe two curved magnets may be positioned at the same vertical height ofthe hard start capacitor replacement unit 1000, 1100 (e.g., such thateach of the curved magnets runs along less than an entire circumferenceof the side wall 1024, 1104, or such that each of the curved magnetsruns along half of the circumference of the side wall 1024, 1104 suchthat the sides of the two magnets make contact with each other). Asmentioned above, one or more of the curved magnets may be a rare-earthmagnet that include neodymium, while the disk shaped magnets may be madefrom one or more ceramic compounds (e.g., ferrite), although othermaterials are also possible. In some implementations, the neodymiumcurved magnets may have a relative higher (e.g., a substantially higher)degree of magnetic attraction as compared to that of the disk shapedceramic magnets.

While the various disc shapes magnets and curved magnets have largelybeen described as being placed inside of the case 1006, 1106 of the hardstart capacitor replacement unit 1000, 1100, in some implementations,one or more of the magnets described herein may be placed outside of thecase 1006, 1106. For example, one or more of the disk shaped magnets maybe positioned on a bottom (e.g., outside) surface of the bottom wall1004, 1164 of the case 1006, 1106. The magnets may be affixed to theoutside of the case 1006, 1106 by the strength of magnetic attraction.In some implementations, one or more mounting mechanisms (e.g.,brackets), an adhesive, an epoxy, one or more fasteners, etc. may beused to assist in mounting the magnets to the outside of the case 1006,1106. For example, one or more brackets may be used to mount the one ormore magnets to the exterior of the case 1006, 1106. In someimplementations, a liner (e.g., such as the liner described above) maybe used to assist in mounting the one or more magnets to the case 1006,1106.

Similarly, one or more of the curved magnets may be positioned on anoutside surface of the side wall 1024, 1104 of the case 1006, 1106. Themagnets may be affixed to the outside of the case 1006, 1106 by thestrength of magnetic attraction. In some implementations, one or moremounting mechanisms (e.g., brackets), an adhesive, an epoxy, one or morefasteners, etc. may be used to assist in mounting the magnets to theoutside of the case 1006, 1106. For example, one or more brackets may beused to mount the one or more magnets to the exterior of the case 1006,1106. In some implementations, a liner (e.g., such as the linerdescribed above) may be used to assist in mounting the one or moremagnets to the case 1006, 1106.

While the curved magnets have been described as having a curved shapethat substantially interfaces with the side wall 1024, 1104 of the case1006, 1106, in some implementations, a first wall of one or more of thecurved magnets may have a curved shape that interfaces with the sidewall 1024, 1104 of the case 1006, 1106, and an opposite wall (e.g., awall opposite of the curved wall of the one or more magnet) may have asubstantially flat shape. The substantially flat shape may allow thecase 1006, 1106 to interface with a flat surface of a separate object(e.g., an air conditioning system). For example, in someimplementations, one or more of the curved magnets may be positioned onan exterior of the side wall 1024, 1104 of the case 1006, 1106 (e.g., asdescribed above). The opposite surface of the curved magnet may have aflat shape that can substantially interface with a flatmagnetically-attractive surface, such as a metal wall of an airconditioning unit or system. The flat shape of the opposite surface ofthe one or more magnets may allow the hard start capacitor replacementunit 1000, 1100 to create a sufficient magnetic bond with the airconditioning unit or system, such that the hard start capacitorreplacement unit 1000, 1100 cannot become inadvertently dislodged ormisaligned from its intended mounting position.

In some implementations, one or more of the curved magnets may beconfigured to interface with both an outside of the side wall 1024, 1104of the hard start capacitor replacement unit 1000, 1100 and the bottomwall 1004, 1164 of the hard start capacitor replacement unit 1000, 1100.For example, one or more of the curved magnets may include at least fiverelevant surfaces: a first curved surface (e.g., inside surface) that isconfigured to interface with the outside surface of the side wall 1024,1104, a second flat surface (e.g., inside surface) that is configured tointerface with the bottom wall 1004, 1164, and three additional flatsurfaces (e.g., outside surfaces) that are configured to interface withone or more mounting location (e.g., of one or more surfaces of an airconditioning unit or system). The inside surfaces can allow the magnetto make intimate contact with the case 1006, 1106 of the hard startcapacitor replacement unit 1000, 1100, thereby allowing the one or moremagnets to maintain contact with the hard start capacitor replacementunit 1000, 1100 using one or more of the techniques described above. Thethree outside surfaces may allow the one or more magnets to makeintimate contact with a mounting location, such as a corner mountinglocation that allows a bottom outside surface of the magnet to interfacewith a bottom mounting location, a first side outside surfaceperpendicular to the bottom outside surface to interface with a sidemounting location, and a second side outside surface perpendicular tothe bottom outside surface and the first side surface to interface withanother side mounting location, thereby allowing the hard startcapacitor replacement unit 1000, 1100 to be mounted in a corner targetarea while being placed on a bottom surface of the target area.

In some implementations, the magnet may include two outside surfaces(e.g., without a bottom outside surface) that allows the hard startcapacitor replacement unit 1000, 1100 to be mounted in a corner targetarea without the hard start capacitor replacement unit 1000, 1100necessarily being placed on (e.g., magnetically attracted to) a bottomsurface of the mounting area. In this way, the hard start capacitorreplacement unit 1000, 1100 can be mounted to a corner target area of anair conditioning unit or system while being suspended (e.g., withoutbeing placed on a bottom surface of the mounting area).

As described above, in some implementations, one or more of the curvedmagnets may be a rare-earth magnet that include neodymium, while thedisk shaped magnets may be made from one or more ceramic compounds(e.g., ferrite), although it should be understood that other materialscan additional or alternatively be used for any of the magnets describedherein. In some implementations, the neodymium curved magnets may have arelatively higher (e.g., a substantially higher) degree of magneticattraction as compared to that of the disk shaped ceramic magnets. Sucha configuration may, for example, provide additional magnetic mountingstrength for implementations in which the hard start capacitorreplacement unit 1000, 1100 is side mounted (e.g., mounted to a sidesurface of a target mounting location without the bottom wall 1004, 1164of the case 1006, 1106 making contact with a bottom surface of themounting location), sometimes referred to herein as a suspended mountingconfiguration. The relatively higher degree of magnetic attractionprovided by one or more of the curved magnets may allow the hard startcapacitor replacement unit 1000, 1100 to be mounted in suchconfigurations without becoming dislodged or misplaced from the targetlocation. For example, the relatively higher degree of magneticattraction may prevent the hard start capacitor replacement unit 1000,1100 from sliding down a wall of the mounting location due to theeffects of gravity. In contrast, in implementations in which the bottomwall 1004, 1164 of the hard start capacitor replacement unit 1000, 1100is mounted to a bottom surface of the target mounting location (e.g., ona bottom surface of an air conditioning unit or system), such additionalstrength of magnetic attraction may not be necessary to maintain thecapacitor hard start capacitor replacement unit 1000, 1100 in propermounting configuration. Nonetheless, additional curved magnets may alsobe included to provide additional and/or redundant magnetic attractionfor mounting purposes.

FIG. 12 shows another example of a hard start capacitor replacement unit1200 and a magnet 1202 that is externally mounted toward a bottomportion of the hard start capacitor replacement unit 1200. As describedabove, in some implementations, the hard start capacitor replacementunits described herein may include one or more relays (e.g., potentialrelays, control relays, electronic relays, etc.), such as the electronicrelay 18 of FIG. 1. A relay may be accommodated above a capacitorcontainer of the hard start capacitor replacement unit 1200 within aprojected cylindrical envelope thereof. In some implementations, thehard start capacitor replacement unit 1200 may be configured to accept acylindrical cap that can surround and cover the relay. In someimplementations, the relay can be externally connected to the hard startcapacitor replacement unit 1200. In some implementations, the relay canbe internally connected to the hard start capacitor replacement unit1200.

In some implementations, operations of the relay may be affected bymagnetic fields in the vicinity of the relay. In particular, the magnetsdescribed herein may alter the magnetic field around the relay and causethe relay to operate in a manner that is undesirable. In someimplementations, the positioning of the magnet 1202 toward the bottomportion of the hard start capacitor replacement unit 1200 (e.g., asshown in FIG. 12) and away from the relay mounted toward the top portionof the hard start capacitor replacement unit 1200 may minimize theimpact of the magnetic field created by the magnet 1202 on the operationof the relay, thereby allowing the relay to operate as intended.

The magnet 1202 is a curved magnet 1202 that is mounted to an outsidesurface of a side wall 1262 of a case 1212 of the hard start capacitorreplacement unit 1200 by a cable tie 1206. When the magnet 1202 is in amounted position (e.g., as shown in FIG. 12), a portion of the cable tie1206 resides in an elongated recess 1204 of the magnet 1202. The recess1204 is configured to accept the portion of the cable tie 1206 andassist in preventing the magnet 1202 from sliding upward or downward andout from underneath the cable tie 1206. A remainder of the cable tie1206 wraps around an outer circumference of the case 1212 and applies aninward radial force to the magnet 1202, thereby holding the magnet 1202in place on the outside surface of the side wall 1262 of the case 1212.In some implementations, the magnet 1202 may additionally be affixed tothe case 1212 with the assistance of magnetic attraction. For example,the case 1212 may be made from a material that is magneticallyattractive, and additional mounting strength can be provided by thestrength of magnetic attraction between the magnet 1202 and the case1212.

The magnet 1202 includes the elongated recess 1204 that provides a trackin which a portion of the cable tie 1206 may reside. In the illustratedexample, the recess 1204 includes a plurality of grooves that interfacewith the cable tie 1206 when the cable tie 1206 is positioned therein.

In some implementations, providing magnetic mounting capability for thehard start capacitor replacement unit can provide a number ofadvantages. For example, in some implementations, a component to whichor within which the hard start capacitor replacement unit is to bemounted (e.g., an air conditioning system) may or may not include anarea (e.g., a designated area) that is typically used for mounting thehard start capacitor replacement unit. However, the user may desire tomount the hard start capacitor replacement unit elsewhere. By providingmagnetic mounting capability, the number of options for mounting can begreatly increased.

In some implementations, the hard start capacitor replacement unit ismounted at locations that include metallic and/or magnetic objects. Suchobjects may impact the performance of the hard start capacitorreplacement unit. In some implementations, the user may desire to mountthe hard start capacitor replacement unit at a particular location suchthat particular operating conditions are achieved. Magnetic mountabilityof the hard start capacitor replacement unit can allow the user to mountthe hard start capacitor replacement unit at such locations. In someexamples, the hard start capacitor replacement unit can be mounted atlocations that allow for shorter conductive connections (e.g., wires)between the capacitance value terminals and common cover terminal andthe device to which the hard start capacitor replacement unit isconnected. Without such flexibility in possible mounting locations, thewires may be excessively long and may be susceptible to being cut orbroken along with being susceptible to noise and/or distortions.

Regarding FIG. 13, a perspective view of a hard start capacitorreplacement unit 1300 is shown connected to a relay 1302 (e.g., similarto the relay 18 of FIG. 1, an electronic relay, etc.), which is externalto the container 1304. In some implementations, external relays may bepreferable to internal relays because the container 1304 can have asmaller size and geometry if it does not need space for the relay 18.Therefore, the hard start capacitor replacement unit 1300 may need lessspace for mounting and connecting to the compressor. Additionally, usinga relay external to the container 1304 can allow for different methodsof wiring the relay 18 to the hard start capacitor replacement unit1300. For example, a repairman can have the option to wire, orient,position, etc. the relay 18 to the hard start capacitor replacement unit1300 in different ways (e.g., to different external terminals) as neededfor installation. In the illustrated example, the relay 1302 isexternally connected from the container 1304.

A conductor 1306 electrically connects a common cover terminal 1308 ofthe hard start capacitor to an external terminal 1310 of the potentialrelay 1302. Another conductor 1312 electrically connects one capacitorcover terminal 1314 to the external terminal 1316 of the potential relay1302. A third conductor 1322 electrically connects the external terminal1310 to the compressor motor or the motor run capacitor and a fourthconductor 1324 electrically connects external terminal 1320 to acompressor motor or the motor run capacitor. A bleeder resistor 1318connects the external terminal 1310 to the external terminal 1320 of thepotential relay 1302.

Referring back briefly to FIG. 4 and FIG. 9, the bleeder resistor 1318partially or fully discharges a connected capacitor, a capacitor of thehard start capacitor 1300, etc. in a similar manner as bleeder resistors78 and 98. In FIG. 4 and FIG. 9, for example, the hard start capacitoris electrically connected to the start terminal 62 of the motor 60, therun terminal 64 of the motor 60, etc. The external terminals 1318, 1314,and 1308 of electronic relay 1302 can be internally connected, e.g., ina similar manner to which terminals T-1, T-2, and T-5 are internallyconnected in relay 18. For example, in FIG. 4, the external terminalsT-1 and T-2 are internally connected with contacts 70 and 72. Theelectronic relay 18 also includes an external terminal T-5, and thedv/dt between terminals T-2 and T-5 and controls the opening and closingof the contacts of the relay 18.

Over the course of a relay's use, it can become damaged through normalwear and tear. For example, a relay can malfunction due to environmentalfactors (e.g., humidity, cold, etc.). For example, the connections on arelay can become worn, and the relay may start to malfunction (e.g.,mechanically stick). Briefly referring to FIG. 4, the relay could bestuck if contacts 70 and 72 are closed by contact bar 74 and do not openagain, are resistant to opening again, etc. If the relay is stuck, thehard start capacitor is not removed from the circuit and remains inparallel with the run capacitor during operation (when only the runcapacitor should be connected). By the hard start capacitor not beingremoved from the circuit, the motor compressor, other system components,etc. could become damaged. For example, a compressor motor running withthe hard start capacitor not being removed from the circuit may continueto properly function for a relatively short period of time (e.g., 1-16seconds) before failing or being damaged. In another example, if a relayis stuck open (e.g., the contacts are open and do not close again, areresistant to closing again, etc.), then the hard start capacitor is notadded in parallel with the run capacitor during start operations. Acompressor motor using only the run capacitor for start operations maycontinue to properly function for a relatively short period of timebefore failing or being damaged.

One or more techniques may be employed to properly disconnect the hardstart capacitor from being connected to the circuit (e.g., beingconnected to the compressor and the motor run capacitor). In onearrangement, one or more electrical and/or electronic components may beintroduced to assist with properly removing the hard start capacitorfrom the circuit. One example of such an electrical component is a fuse.If a failure occurs (e.g., a capacitive failure, the relay malfunctions,the relay contacts mechanically stick, the relay contacts become weldedtogether, etc.), the fuse can open an electrical connection as currentincreases and disconnect the hard start capacitor from the circuit,preventing damage to the compressor motor, the run capacitor, etc. Forexample, the fuse can burn out at a threshold current or thresholdvoltage. The increased current or voltage can cause the fuse to burn andopen an electrical connection, or the increased current or voltage cancause the electrical connection to break.

Also, in some implementations, the run capacitor may become disconnectedfrom the compressor motor or may fail (e.g., due to reaching itsexpected (e.g., rated) end of life, or for other reasons). In suchsituations, it may be beneficial for the start capacitor to bedisconnected from the compressor motor. In other words, it may bebeneficial for the circuit that includes the start capacitor and thecompressor motor to be broken, for example, by severing at least anelectrical ground connection. For example, the capacitance provided bythe start capacitor may continue to cause compressor motor to operatethe compressor motor. In such situations, the compressor motor would berunning without a run capacitor, and the capacitance provided by thestart capacitor may be unsuitable for continuous prolonged use by thecompressor motor in its running state. In some implementations, thecapacitance value provided by the start capacitor may cause thecompressor motor to fail (e.g., “burn out”) after prolonged use due toexcessive current draw and overheating. In some implementations, theexcessive current draw and overheating may cause the compressor motor toshut off due to a thermal overload switch. However, even with theprotection of the thermal overload switch, the compressor motor maycontinue to be power cycled due to the start capacitance provided by thestart capacitor. To avoid damage to and/or repeated power cycling of thecompressor motor, the start capacitor may be connected to the compressormotor in such a way that the start capacitor is automaticallydisconnected from the compressor motor when the run capacitor is nolonger connected to the compressor motor. As such, the start capacitorwill not cause the compressor motor to restart and/or to continue to runby using the capacitance provided by the start capacitor in place of thenow disconnected run capacitor until/unless the run capacitor isreplaced and the electrical connection between the compressor motor andthe start capacitor is reestablished.

Different types of fuses can be used which can open electricalconnections for a plurality of reasons. For example, the fuse can openan electrical connection at, e.g., a voltage cutoff, a current cutoff, athermal cutoff, a threshold current for a predetermined period of time(i.e., a slow blow fuse), etc. For example, the fuse can open anelectrical connection upon a threshold voltage. In another example, thefuse can open an electrical connection upon a threshold current. Inanother example, the fuse can open an electrical connection upon athreshold current and threshold voltage. For example, the fuse may onlyopen an electrical connection when both the current exceeds thethreshold current and the voltage exceeds a threshold voltage. Inanother example, the fuse can open an electrical connection upon athreshold temperature. In another example, the fuse can open anelectrical connection upon a threshold voltage and a thresholdtemperature. For example, the fuse may only open an electricalconnection when both the voltage exceeds a threshold voltage and thetemperature exceeds a threshold temperature. In another example, thefuse can open an electrical connection upon a threshold current and athreshold temperature. For example, the fuse may only open an electricalconnection when both the current exceeds a threshold current and thetemperature exceeds a threshold temperature. In another example the fusecan open an electrical connection upon a threshold current for apredetermined amount of time. For example, the fuse may only open anelectrical connection when the current exceeds a threshold current for apredetermined amount of time. In another example the fuse can open anelectrical connection upon a threshold voltage for a predeterminedamount of time. For example, the fuse may only open an electricalconnection when the voltage exceeds a threshold voltage for apredetermined amount of time. In another example the fuse can open anelectrical connection upon a threshold temperature for a predeterminedamount of time. For example, the fuse may only open an electricalconnection when the voltage exceeds a threshold voltage for apredetermined amount of time. Different materials can be selected forthe fuse to achieve the desired characteristics.

Various events can trigger a fuse to open an electrical connection(e.g., a compressor motor failure, a relay failure, a capacitor failure,etc.). For example, if the relay becomes stuck, a fuse (e.g., a slowblow fuse) may be used to disconnect the hard start capacitor from thecircuit to prevent damage. A slow blow fuse is a fuse that opens anelectrical connection when the current exceeds a threshold current for apredetermined period of time. The fuse can have a variety of electricalthresholds that determine when the fuse opens an electrical connection.For example, the fuse can have a variety of voltage thresholds (e.g.,200V (volts), 250V, 300V, etc.). The fuse can also have a variety ofamperage thresholds (e.g., 3 A (amperes), 4 A, 5 A, 10 A, etc.).Further, the slow blow fuse can have a variety of constructionparameters (e.g., PVC insulation, rubber insulation, etc.) to achievethe desired thresholds.

A number of suitable fuses can be used to properly disconnect the hardstart capacitor from being connected to the circuit. In someimplementations, a desirable fuse will open an electrical connectionupon the current traveling through the hard start capacitor replacementunit for a predetermined time period of about 0.5-5 seconds (e.g., 3seconds). This is a short enough time to reduce or prevent damage to thecompressor motor, other system components, etc. This is also a longenough period of time that the fuse does not open an electricalconnection during start operations of the motor. For example, a 250V—5 Afuse can be used, with, e.g., two layers of PVC heat-shrink insulation(e.g., as produced by LittleFuse, part number 0313005.HXP). Other fusescan also be used as well. For example, a 4 A slow blow fuse with twolayers of PVC heat-shrink insulation can be used (e.g., as produced byBel Fuse, part number GSA(P) 4-R). Another example of a suitable fuse isa 10 A slow blow fuse (e.g., as produced by Bel Fuse, part number GSA(P)10-R). Other amperage thresholds can also be used, for example, a 5 Aslow blow fuse can be used (e.g., as produced by Bel Fuse, part numberGSA(P) 5-R).

Other construction parameters can also create slow blow fuses. Forexample, ceramic body fuses, which are fuses with an exterior ceramicbody (with a size of, e.g., 0.25 inches by 1.25 inches) can createsuitable slow blow fuses. Another example is a glass body fuse, which isa fuse with an exterior glass body (with a size of, e.g., 0.25 inches by1.25 inches) that can create suitable slow blow fuses.

Other types of fuses can also be used as fuses. For example, a fuse thatwill open an electrical connection when the voltage exceeds a thresholdvoltage for a predetermined amount of time can be suitable fordisconnect the hard start and the circuit. In another example, a fusethat will open an electrical connection when the temperature exceeds athreshold temperature for a predetermined amount of time can be suitablefor disconnecting the hard start capacitor and the circuit.

One technique of connecting a fuse (e.g., a slow blow fuse) to thecircuit is mounting a fuse to the external relay. Mounting the fuse toan external relay can be advantageous because the fuse is easy toreplace. In other embodiments, the fuse can be added to other parts ofthe circuit. For example, the fuse can be external to the capacitorcontainer. In another example, the fuse can be internal to the capacitorcontainer. In another example, the fuse can be internal to the relay.

FIG. 14A illustrates a front view of a relay 1400 with a fuse 1402mounted to the relay. FIG. 14B illustrates a back view of the relay 1400with the fuse 1402 mounted to the relay 1400 and a bleeder resistor1404, which is similar to bleeder resistors 78 and 98 of FIGS. 4 and 9,respectively, and the bleeder resistor 1318 of FIG. 13. The fuse 1402can be, for example, a slow blow fuse. The fuse 1402 is connected to thecircuitry of the relay 1400 so that if a failure occurs (e.g., acapacitive failure, the relay malfunctions, mechanically sticks, weldsclosed, arcs, etc.), the fuse can open an electrical connection,preventing damage to other components of the system. For example, thefuse 1402 can be electrically connected to an external terminal (e.g.,T-1 or T-2) of the relay and the contacts of the relay. When the fuseopens an electrical connection, the contacts of the relay are no longerelectrically connected to the external terminals of the relay. FIG. 14Cillustrates a side view of the external relay 1400 and illustrates abracket 1406 which can be used to mount the external relay to otherobjects. FIG. 14D illustrates a side view of the external relay 1400 andshows the bleeder resistor 1404. FIG. 14E illustrates a top view of theexternal relay 1400, fuse 1402, and bleeder resistor 1404. FIG. 14Fillustrates a bottom view of the external relay 1400 and illustrates abottom view of the bracket 1406.

Regarding FIG. 15, a perspective view of a hard start capacitor 1500 isshown connected to a relay 1502 (e.g., similar to hard start capacitor1300 and relay 1302 of FIG. 13). The relay can be, e.g., a potentialrelay, an electronic relay, etc. However, in the illustrated example,the relay 1502 includes a fuse 1504 (e.g., a slow blow fuse) mounted tothe relay 1502 and connected to the circuitry of the relay 1502 (e.g.,similar to the fuse 1402 of FIGS. 14A-E). For example, the fuse 1504 canbe mounted to the enclosure 1506 of the relay 1502. Therefore, upon afailure (e.g., a capacitive failure, the relay malfunctions, thecontacts mechanically stick, etc.), the fuse can open an electricalconnection, preventing damage to other components of the system.Different fuses can be mounted to the relay 1502. For example, differentratings of fuses may be used depending on the wiring of the system andthe amperage used by the start capacitor. For example, systems withgreater capacitance require greater amperage. Wiring multiple capacitorsin parallel requires a greater current than a single capacitor. Forexample, in systems with connections between multiple capacitorterminals on a hard start capacitor (e.g., wiring similar to FIG. 8), afuse with a higher rating (e.g., 10 A fuse) may be used in the circuit.In this case, the fuse would be intended for use when a hard startcapacitor will have multiple connections between capacitor terminals andrequire a higher amperage. In systems without connections betweenmultiple capacitor terminals on a hard start capacitor (e.g., wiringsimilar to FIG. 5), a fuse with a lower rating (e.g., a 5 A fuse) may beused. In this case, the fuse would be intended for use when a hard startcapacitor will not have multiple connections between capacitor terminalsand will require a lower amperage.

A hard start capacitor can be electrically connected to a compressormotor and a run capacitor in a variety of ways. For example, the hardstart capacitor can be electrically connected to a terminal of the runcapacitor. Suitable run capacitors are described in prior U.S. Pat. No.7,203,053, which is incorporated herein by reference in its entirety.FIG. 16 illustrates an exemplary run capacitor 1600. The run capacitor1600 has a capacitive element 1602 having a plurality of capacitorsections, each having a capacitance value. In the preferred embodimentdescribed herein, the capacitive element 1602 has six capacitor sections1604, 1606, 1608, 1610, 1612, 1614. The capacitive element 1602 is awound cylindrical element manufactured by extension of the techniquesdescribed in U.S. Pat. Nos. 3,921,041, 4,028,595, 4,352,145 and5,313,360, each of which is incorporated herein by reference in itsentirety. Those patents relate to capacitive elements having twocapacitor sections rather than a larger plurality of capacitor sections,such as the six capacitor sections 1604, 1606, 1608, 1610, 1612, 1614 ofthe capacitive element 1602. Accordingly, the capacitive element 1602has a central spool, mandrel, etc. 1616, which has a central opening1618. First and second dielectric films, each having a metalized layeron one side thereof, are wound in cylindrical form on the mandrel 1616with the non-metalized side of one film being in contact with themetalized side of the other. Selected portions of one or both of themetalized layers are removed in order to provide a multiple sectioncapacitive element. Element insulation barriers are inserted into thewinding to separate the capacitor sections, the element insulationbarriers also assuming a cylindrical configuration. Five elementinsulation barriers 1620, 1622, 1624, 1626, 1628 are provided toseparate the six capacitor sections 1604, 1606, 1608, 1610, 1612, 1614,with element insulation barrier 1620 separating capacitor sections 1604and 1606, element insulation barrier 1622 separating capacitor sections1606 and 1608, element insulation barrier 1624 separating capacitorsections 1608 and 1610, element insulation barrier 1626 separatingcapacitor sections 1610 and 1612, and element insulation barrier 1628separating capacitor sections 1612 and 1614.

The element insulation barriers are insulating polymer sheet material,which in the capacitive element 1602 is polypropylene having a thicknessof 0.005 inches, wound into the capacitive element 1602. Thickness of0.0025 to 0.007 may be used. Other materials may also be used. Thebarriers each have about 2¾-4 wraps of the polypropylene sheet material,wherein the element insulation barriers have a thickness of about 0.013to 0.020 inches. The barriers 1620, 1622, 1624, 1626, 1628 are thickerthan used before in capacitors with fewer capacitor sections. Theimportant characteristic of the barriers 1620, 1622, 1624, 1626, 1628 isthat they are able to withstand heat from adjacent soldering withoutlosing integrity of electrical insulation, such that adjacent sectionscan become bridged.

The metalized films each have one unmetalized marginal edge, such thatthe metalized marginal edge of one film is exposed at one end of thewound capacitive element 1602 and the metalized marginal edge of theother film is exposed at the other end of the capacitive element 1602.At the lower end of the capacitance element 1602, the barriers 1620,1622, 1624, 1626, 1628 do not extend from the film, and an elementcommon terminal is established contacting the exposed metalized marginaledges of one metalized film of all the capacitor sections 1604, 1606,1608, 1610, 1612, 1614. The element common terminal is preferably a zincspray applied onto the end of the capacitive element 1602.

At the top end of the capacitive element 1602, the element insulationbarriers 1620, 1622, 1624, 1626, 1628 extend above the wound metalizedfilm. An individual capacitor element section terminal is provided foreach of the capacitive sections 1604, 1606, 1608, 1610, 1612, 1614, alsoby applying a metallic spray (e.g., a zinc spray) onto the end of thecapacitive element 1602 with the zinc being deployed on each of thecapacitor sections 1604, 1606, 1608, 1610, 1612, 1614 between andadjacent the element insulation barriers 1620, 1622, 1624, 1626, 1628.The element section terminals are identified by numerals 1630, 1632,1634, 1636, 1638, 1640. Element section terminal 1630 of capacitorsection 1604 extends from the outer-most element insulation barrier 1620to the outer surface of the capacitive element 1602, and the elementsection terminal 1640 of capacitor section 1614 extends from theinner-most element insulation barrier 1628 to the central mandrel 1616.Element section terminals 1632, 1634, 1636, 1638, 1640 are respectivelydeployed on the capacitor sections 1606, 1608, 1610, 1612, 1614.

Conductors preferably in the form of six insulated wires each have oneof their ends respectively soldered to the element section terminals1630, 1632, 1634, 1636, 1638, 1640. The thickness of the polypropylenebarriers 1620, 1622, 1624, 1626, 1628 resists any burn-through as aresult of the soldering to connect wires to the terminals 1630, 1632,1634, 1636, 1638, 1640.

The insulation of the wires may be color coded to facilitate identifyingwhich wire is connected to which capacitor section. The wire connectedto element section terminal 1640 of capacitor section 1604 has blueinsulation, the wire connected to element section terminal 1632 ofcapacitor section 1606 has yellow insulation, the wire connected toelement section terminal 1634 of capacitor section 1608 has redinsulation, the wire connected to element section terminal 1636 ofcapacitor section 1610 has white insulation, the wire connection toelement section terminal 1638 of capacitor section 1612 has whiteinsulation, and the wire connected to element section terminal 1640 ofcapacitor section 1614 has green insulation.

The capacitive element 1602 is further provided with foil stripconductor 1642, having one end attached to the element common terminalat 1644. The foil strip conductor 1642 is coated with insulation, exceptfor the point of attachment 1644 and the distal end thereof. Theconductor connected to the outer capacitor element section 1604 and itsterminal 1630 may also be a foil strip conductor. If desired, foil, wireconductors, etc. may be utilized for all connections.

In the capacitive element 1602 used in the run capacitor 1600, thecapacitor section 1604 has a value of about 25.0 microfarads (e.g.,about 20 microfarads to about 30 microfarads) and the capacitor section1606 has a capacitance of about 20.0 microfarads (e.g., about 15microfarads to about 25 microfarads). The capacitor section 1608 has acapacitance of about 10.0 microfarads (e.g., about 5 microfarads toabout 15 microfarads). The capacitor section 1610 has a capacitance ofabout 5.5 microfarads (e.g., about 2.5 microfarads to about 10microfarads), but can be identified as having a capacitance of 5.0microfarads for purposes further discussed in U.S. Pat. No. 10,586,655,incorporated herein in its entirety by reference. The capacitor section1612 has a capacitance of about 4.5 microfarads (e.g., about 2.5microfarads to about 10 microfarads) but is labeled as having acapacitance of 5 microfarads, e.g., for purposes described in U.S. Pat.No. 10,586,655, incorporated herein in its entirety by reference. Thecapacitor section 1614 has a capacitance of 2.8 microfarads (e.g., about1 microfarad to about 5 microfarads). The capacitor section 1604 withthe largest capacitance value also has the most metallic film, and istherefore advantageously located as the outer section or at least one ofthe three outer sections of the capacitive element 1602.

The run capacitor 1600 also has a case 1646 having a cylindrical sidewall 1648, a bottom wall 1650, and an open top 1652 of side wall 1648.The case 1646 is formed of aluminum and the cylindrical side wall 1648has an outside diameter of 2.50 inches. This is a very common diameterfor capacitors of this type, wherein the run capacitor 1600 will bereadily received in the mounting space and with the mounting hardwareprovided for the capacitor being replaced. Other diameters may, however,be used, and the case may also be of a suitable material (e.g.,plastic).

The capacitive element 1602 with the wires and the foil strip 1642 arereceived in the case 1646 with the element common terminal adjacent thebottom wall 1664 of the case. An insulating bottom cup 1654 ispreferably provided for insulating the capacitive element 1602 from thebottom wall 1650, the bottom cup 1654 having a center post 1656 that isreceived in the center opening 1618 of the mandrel 1616, and anup-turned skirt 1658 that embraces the lower side wall of thecylindrical capacitive element 1602 and spaces it from the side wall1648 of the case 1646.

An insulating fluid 1660 is provided within the case 1646, at leastpartly and preferably substantially surrounding the capacitive element1602. The fluid 1660 may be the fluid described in U.S. Pat. No.6,014,308, incorporated herein by reference in its entirety. In otherembodiments, the fluid 1660 can be other fluids, such as polybutene,etc.

The run capacitor 1600 also has a pressure interrupter cover assembly1662. The cover assembly 1662 includes a deformable circular cover 1664having an upstanding cylindrical skirt 1666 and a peripheral rim 1668.The skirt 1666 fits into the open top 1652 of the cylindrical side wall1648 of case 1646, and the peripheral rim 1668 is crimped to the opentop 1652 of the case 1646 to seal the interior of the run capacitor 1600and the fluid 1660 contained therein.

The pressure interrupter cover assembly 1662 includes seven coverterminals mounted on the deformable cover 1664. A common cover terminal1670 is mounted generally centrally on the cover 1664, and section coverterminals, each respectively corresponding to one of the capacitorsections 1604, 1606, 1608, 1610, 1612, 1614, are mounted at spaced apartlocations surrounding the common cover terminal 1670. The section coverterminal 1672 has three upstanding blades mounted on the upper end of aterminal post. The terminal post has a distal end, opposite the blades.The cover 1664 has an opening for accommodating the terminal post, andhas a beveled lip surrounding the opening. A shaped silicone insulatorfits snuggly under the cover in the beveled lip and the terminal postpasses through the insulator. On the upper side of the cover, aninsulator cup 1674 also surrounds the post, and the insulator cup sitsatop the silicone insulator; thus, the terminal 1672 and its terminalpost are well insulated from the cover 1664. The other cover sectionterminals are similarly mounted with an insulator cup and a siliconeinsulator. The pressure interrupter cover assembly 1662 provides suchprotection for the run capacitor 1600 and its capacitive element 1602.Outgassing can cause the circular cover 1664 to deform upwardly into agenerally domed shape. When the cover 1664 deforms, the terminal postsare also displaced upwardly from the disconnect plate 1676, and the weldconnection of the distal end of common cover terminal post to the distalend foil lead from the element common terminal 1636 of the capacitiveelement 1602 is broken, and the welds between the foil tabs and theterminal posts of the section cover terminals are also broken. Locatingthe common cover terminal 1670 in the center of the cover 1664, wherethe deformation of the cover 1664 is the greatest, ensures that thecommon cover terminal connection is broken both first and with certaintyin the event of a failure of the capacitive element 1602.

The common cover terminal 1670 has four blades in this example, and aterminal post that passes through a silicone insulator. The common coverterminal 1670 mounts cover insulator barrier 1678 that includes anelongated cylindrical center barrier cup 1680 surrounding and extendingabove the blades of the common cover terminal 1670, and six barrier fins1682 that extend respectively radially outwardly from the elongatedcenter barrier cup 1680 such that they are deployed between adjacentsection cover terminals. This provides additional protection against anyarcing contact between adjacent section cover terminals, with the commoncover terminal 1670, etc. Alternatively, the common cover terminal 1670may be provided with an insulator cup 1680, preferably extending abovethe blades but with no separating barrier fins, although the barrierfins 1682 are preferred. The terminal post extends through an opening inthe bottom of the base of the insulating barrier cup 1680, and throughthe silicone insulator, to a distal end.

The pressure interrupter cover assembly 1662 has a fiberboard discthrough which the terminal posts of the section cover terminals extend.The disc may be also fabricated of other suitable material, such aspolymers. The terminal posts are configured as rivets with rivet flangesfor assembly purposes. The terminal posts are inserted through the disc,insulators, insulator cups and barrier cup 1680, and the cover terminalsare spot welded to the ends of the rivets opposite the rivet flanges.Thus, the rivet flanges secure the cover terminals in the cover 1664,together with the insulator barrier 1678, insulator cups 1674, andsilicone insulators. The fiberboard disc facilitates this assembly, butmay be omitted, if desired. The distal ends of the terminal posts arepreferably exposed below the rivet flanges.

The cover assembly 1662 has a disconnect plate 1676. The disconnectplate 1676 is made of a rigid insulating material, such as a phenolic,is spaced below the cover 1664 by a spacer in the form of a skirt. Thedisconnect plate 1676 is provided with openings accommodating the distalends of the terminal posts. The disconnect plate 1676 is furtherdescribed in prior U.S. Pat. No. 10,586,655, incorporated herein byreference in its entirety.

In prior capacitors having three or fewer capacitor sections, theconductors between the capacitor sections and the terminal posts weregenerally foil strips, such as the one used for the common elementterminal 1636 of the capacitive element 1602 herein. The foil stripswere positioned on a breaker plate over the distal ends of terminalposts, and were welded to the distal ends of the terminal posts. In runcapacitor 1600, the distal end 1644 of the foil strip 1642 is connectedto the distal end of terminal post by welding, as in prior capacitors.

The wires may not be well-configured for welding to the distal ends ofthe terminal posts of the cover section terminals. However, the wiresare desirable in place of foil strips because they are betteraccommodated in the case 1646 and have good insulating properties,resist nicking and are readily available with colored insulations. Inorder to make the necessary connection of the wires to their respectiveterminal posts, foil tabs are welded to each of the distal ends of theterminal posts of the section cover terminals and the guides are helpfulin positioning the foil tabs for the welding procedure. The attachmentmay be accomplished by welding the distal end of a foil strip to theterminal post, and then cutting the foil strip to leave the foil tab.Thereafter, the conductor of the wire is soldered to the tab, by solder.The insulation of the wire has been stripped to expose the conductor.The other wires are similarly connected to their respective coversection terminals. Alternatively, the foil tabs may be soldered to thewires and the tabs may then be welded to the terminal posts, if desired,other conductive attachment may be employed, etc.

Accordingly, each of the capacitor sections 1604, 1606, 1608, 1610,1612, 1614 is connected to a corresponding section cover terminal by arespective one of color coded wires. The insulator cups 1674 associatedwith each of the section cover terminals are also color coded, using thesame color scheme as used in the wires. This facilitates assembly, inthat each capacitor section and its wire conductor are readilyassociated with the correct corresponding section cover terminal, sothat the correct capacitor sections can be identified on the cover tomake the desired connections for establishing a selected capacitancevalue.

The connections of the wires and the foil to the terminal posts are madeprior to placing the capacitive element 1602 in the case 1646, addingthe insulating fluid 1660, and sealing the cover 1664 of cover assembly1662 to the case 1646. The case 1646 may be labeled with the capacitancevalues of the capacitance sections 1604, 1606, 1608, 1610, 1612, 1614adjacent the cover terminals, such as on the side of case 1646 near thecover 1664, on the cover 1664, etc.

The run capacitor 1600 may be used to replace a failed capacitor of anyone of over two hundred different capacitance values, including bothsingle and dual applications. Therefore, a serviceman is able to replacevirtually any failed capacitor he may encounter as he makes servicecalls on equipment of various manufacturers, models, ages and the like.

As noted above, the run capacitor 1600 is expected to be used mostwidely in servicing air conditioning units. Air conditioning unitstypically have two capacitors; a capacitor for the compressor motorwhich may or may not be of relatively high capacitance value and acapacitor of relatively low capacitance value for a fan motor. Thecompressor motor capacitors typically have capacitances of from 20 toabout 60 microfarads. The fan motor capacitors typically havecapacitance values from about 2.5 to 12.5 microfarads, and sometimes ashigh as 15 microfarads, although values at the lower end of the rangeare most common.

FIG. 17A illustrates a schematic circuit diagram illustratingconnections of a circuit 1700. The circuit 1700 includes connectionsbetween a hard start capacitor 1702, a run capacitor 1704, and acompressor motor 1706 (e.g., of an air conditioning system). In theillustrated example, the hard start capacitor 1702 and the run capacitor1704 are electrically connected in parallel to the compressor motor1706. The circuit 1700 also includes a fuse 1708 (e.g., a slow blow fuseas described above) that is electrically connecting the hard startcapacitor 1702 and the compressor motor 1706. The circuit 1700 alsoincludes a relay 1710 (e.g., a relay as described in FIGS. 4 and 9) Ifthe fuse 1708 opens an electrical connection due to a failure (e.g., acompressor motor failure, a start capacitor failure, a run capacitorfailure, a relay malfunction, etc.), the hard start capacitor 1702 iselectrically disconnected from the circuit, preventing damage to thecompressor motor, other system components, etc. For example, the fuse1708 can open the electrical connection between the hard start capacitor1702 and the compressor motor 1706, which will remove the hard startcapacitor 1702 from the circuit. This can prevent the start capacitorfrom keeping the compressor running despite failure of the runcapacitor, for example.

FIG. 17B illustrates a similar schematic circuit diagram of connectionsof a circuit 1720, which includes the hard start capacitor 1702, the runcapacitor 1704, and the compressor motor 1706. The circuit 1720 includesthe fuse 1708 electrically connecting the hard start capacitor 1702 andthe run capacitor 1704. The circuit 1720 also includes a relay 1710. Ifthe fuse 1708 opens an electrical connection due to a failure (e.g., acompressor motor failure, a start capacitor failure, a run capacitorfailure, etc.), the hard start capacitor 1702 is electricallydisconnected from the circuit (e.g., electrically disconnected from therun capacitor), preventing damage to the compressor motor and othersystem components. For example, the fuse 1708 will open the electricalconnection between the hard start capacitor 1702 and the run capacitor1704, which will remove the hard start capacitor 1702 from the circuit.In some implementations, the capacitors 1702, 1704 can have moreterminals. The reduced number of terminals used in the drawings issimply for illustration. The circuits 1700, 1720 demonstrate that a fusecan be electrically connected to either electrical connection betweenthe relay 1710 and the run capacitor 1704. For example, the fuse 1708can be connected to the common terminal of the run capacitor 1704, or,the fuse 1708 can be connected to one or more of the cover terminals ofthe run capacitor 1704. Similar electrical connections may beimplemented to the terminals of the compressor 1706; for example thefuse 1708 may be connected to a common terminal of the compressor 1706or the fuse may connected to another terminal of the compressor (e.g., ahigh side terminal). While a single fuse is used in theseimplementations, multiple fuses can be employed. For example, one fusecould electrically connect the relay 1708 to the common terminal of therun capacitor 1704, and, a second fuse 1708 could electrically connectthe relay to one or more cover terminals of the run capacitor 1704.

Some motor run capacitors have a booster terminal (e.g., a second commonterminal that is electrically connected to the first common terminal),which can electrically connect and electrically disconnect equipmentthat is external to the run capacitor from a circuit. Examples of runcapacitors with booster terminals are further described in U.S. Pat. No.10,586,655, incorporated herein by reference in its entirety.

For example, FIG. 18 shows a schematic circuit diagram illustratingconnections among a start capacitor 1802 with terminals 1804, 1806, arun capacitor 1808 with a common cover terminal 1810 and a coverterminal 1812, the run capacitor 1808 including a booster terminal 1814,and a compressor motor 1816 (e.g., of an air conditioning system) havingterminals 1818, 1820. In some implementations, the capacitors 1802, 1808can have more terminals. The reduced number of terminals is simply forillustration. In the illustrated example, the booster terminal 1814 isconnected to a common cover terminal 1810 of the run capacitor. Aconnection 1822 (e.g., provided by one or more conductors) is locatedbeneath a cover of the run capacitor 1808. When the system isoperational, the capacitor of the hard start capacitor 1802 and thecapacitor (e.g., the herm capacitor) of the run capacitor 1808 areconnected in parallel. When the run capacitor 1808 fails, as shown inthe illustration, connections are broken, and the start capacitor 1802is not electrically connected to the compressor 1816, as shown. Inparticular, the common terminal's connection (of the run capacitor 1808)to ground is broken, thereby resulting in the start capacitor 1802 beingelectrically disconnected from the compressor 1806.

In some embodiments, the booster terminal 1814 includes indicia tosignify that it is related to safety and is a safety feature. In someembodiments, the booster terminal 1824 is colored a designated color(e.g., orange) to signify that it is a safety feature. For example, thedesignated color can signify that the booster terminal 1814 removesequipment from the circuit in response to a failure (e.g., a failure ofthe run capacitor 1808). In other embodiments, the booster terminal 1814includes a label to signify that it is a safety feature.

To prevent damage to components of the circuit (e.g., the motor) due toa failure (e.g., a failure of the motor, a failure of the run capacitor,a failure of the start capacitor, a relay malfunction, etc.), a fuse canbe included in the circuit of FIG. 18 in a variety of ways. For example,in the illustrated embodiment, a fuse 1824 is electrically connected toa relay 1826 (e.g., similar to relays described above in FIGS. 4 and 9).The fuse 1824 can be electrically connecting a terminal (e.g., theterminal 1804) of the start capacitor and the terminal 1820 of the motor1816. If the fuse 1824 opens an electrical connection due to a failure(e.g., a compressor motor failure, a relay failure, a start capacitorfailure, a run capacitor failure, etc.), the hard start capacitor 1802is electrically disconnected from the circuit, preventing damage to thecompressor motor and other system components. For example, the fuse 1824opens the electrical connection between the hard start capacitor 1802and the compressor motor 1816, which will remove the hard startcapacitor 1802 from the circuit.

In some implementations, the fuse 1824 can be electrically connectinganother terminal (e.g., the terminal 1806) of the start capacitor 1802and the booster terminal 1814 of the run capacitor 1808. For example, asshown in FIG. 18A, the fuse 1824 is electrically connecting the relay1826 (e.g., and terminal 1806 of the start capacitor 1802) and thebooster terminal 1814 of the run capacitor 1808. In this implementation,the fuse is electrically connected to the ground terminal 1818 of thecompressor motor. In some implementations, it is advantageous toelectrically connect to the ground terminal 1818. In otherimplementations, it is advantageous to electrically connect to anotherterminal (e.g., the terminal 1820).

The fuse 1824 can also be electrically connected in other parts of thecircuit. In another example, a fuse can be electrically connecting theterminal 1810 of the run capacitor 1808 and the terminal 1818 of themotor. Additionally or alternatively, a fuse can be electricallyconnecting the terminal 1812 of the run capacitor and the terminal 1820of the motor.

Fuses can be connected to a hard start capacitor replacement unit toprovide protection and prevent damage to other electrical components(e.g., a motor, a run capacitor, etc.) that may be connected to the hardstart capacitor replacement unit in the event of a failure (e.g., afailure of the motor, a relay malfunction, etc.). Regarding FIG. 19, atop view of a hard start capacitor replacement unit 1900 is shownconnected to an external relay 1902 and a fuse 1904 and in use with amotor run capacitor and a compressor motor. The wiring in FIG. 19 is onetechnique of connecting a fuse (e.g., a slow blow fuse) to disconnectthe hard start capacitor and a compressor upon a failure (e.g., acapacitive failure, the relay malfunctions, internal connections of therelay mechanically stick). In this illustrated example, a conductor 1906connects a common cover terminal 1908 to an external terminal 1910 (T-5)of a relay 1902 (e.g., a potential relay). Another conductor 1912connects a capacitor cover terminal 1914 to an external terminal 1916(T-1) of the potential relay 1902. A bleeder resistor 1918 connects theexternal terminal 1910 of the potential relay to the external terminal1916 of the potential relay. A conductor 1920 connects the externalterminal 1922 (T-2) of the relay to the compressor motor, the motor runcapacitor, etc. A conductor 1924 connects the fuse 1094 (that isconnected to external terminal 1910) to the compressor motor, the motorrun capacitor, etc.

Referring back briefly to FIG. 4 and FIG. 9, the external terminals1916, 1922, and 1910 of relay 1902 are internally connected withcontacts and that may be closed by a contact bar, e.g., in a similarmanner as relay 18. When the contact bar is closed, hard start capacitor1900 is connected in parallel to the compressor motor and the runcapacitor. When the contact bar is open, hard start capacitor 1900 isdisconnected from the circuit. The conductor 1924 includes the fuse 1904so that while the fuse 1904 is intact, the hard start capacitor 1900 andthe relay 1902 are connected to the compressor motor and the runcapacitor. When the fuse 1904 blows (e.g., is no longer intact), thefuse 1904 halts current flow and removes the relay and hard startcapacitor from the circuit.

In another implementation, the fuse 1904 is placed in another positionwithin the circuit formed by the hard start capacitor, relay, andcompressor; for example, a fuse (e.g., the fuse 1904) can be located inthe conductor 1920. Thereby the fuse 1904 can be connected to externalterminal 1922 (T-2) and the conductor 1920 can be connected to the runcapacitor and/or compressor. Different ratings of fuses may beimplemented in the system depending on the wiring of the system and theamperage used by the start capacitor. For example, systems with greatercapacitance may require greater amperage. For example, in systems withconnections between multiple capacitor terminals on a hard startcapacitor (e.g., wiring similar to FIG. 8), a fuse with a higher rating(e.g., 10A fuse) may be used due to the greater capacitance. In systemswithout connections between multiple capacitor terminals (such as asingle unit capacitor) on a hard start capacitor (e.g., wiring similarto FIG. 5), a fuse with a lower rating (e.g., a 5 A fuse) may be used.

In some implementations, it is beneficial to use an internal relay(e.g., a relay internal to the container of the hard start capacitorreplacement unit), as the relay is more protected from environmentalfactors and related damage when compared to an external relay. RegardingFIG. 20, a top view of a hard start capacitor replacement unit 2000 ispresented having an internally positioned potential relay (not viewable)and an externally positioned fuse 2002. A conductor 2004 includes thefuse 2002 and electrically connects the common cover terminal of thehard start capacitor replacement unit to a compressor motor, the motorrun capacitor, etc. Therefore, if the fuse 2002 opens an electricalconnection due to a failure (e.g., a stuck relay, a capacitor failure),the hard start capacitor replacement unit is no longer connected to thecircuit, preventing damage to the hard start capacitor, the compressormotor, the run capacitor, etc. A conductor 2006 electrically connects acapacitor cover terminal 2008 to the compressor motor, the runcapacitor, etc. In another implementation, the fuse could be includedwith other conductors, e.g., the conductor 2006, to disconnect the hardstart capacitor from the circuit upon a failure (e.g., if the potentialrelay malfunctions such as if the contacts mechanically stick) toprevent damage to, e.g., the compressor motor, if the hard startcapacitor is not removed from the circuit.

A fuse can also be positioned inside the container of the hard startcapacitor replacement unit to reduce the amount of wiring outside thecontainer of the hard start capacitor. Regarding FIG. 21, a bottom viewof a cover assembly 2100 is shown including an internally connectedrelay 2102 (e.g., a potential relay, an electronic relay, etc.) and afuse 2104 that are both internally positioned within the container of ahard start capacitor replacement unit. Referring briefly to FIG. 20, therelay may be positioned with a hard start and the fuse may be locatedexternally. Returning to FIG. 21, a conductor 2106 connects the commoncover terminal 2108 to the external terminal 2110 (T-5) of the relay2102. A conductor 2112 includes the fuse 2104 (e.g., a slow blow fuse)and connects a capacitor cover terminal 2114 to the external terminal2116 (T-2) of the relay. Therefore, if the fuse 2104 opens an electricalconnection due to a failure, e.g., due to a stuck relay, the circuitwithin the hard start capacitor replacement unit is broken. Therefore,current flow through the hard start capacitor replacement unit ishalted, preventing damage to other system components, e.g., the motor. Aconductor 2118 connects a second capacitor cover terminal 2120 to theexternal terminal 2122 (T-1) of the relay 2102. A bleeder resistor 2124connects the external terminal 2110 of the relay to the externalterminal 2122 (T-1) of the relay 2102. Referring back briefly to FIG. 1,FIG. 4, and FIG. 9, the relay 2102 may operate in a manner similar tothe electronic relay 18. For example, the external terminals 2120, 2116,and 2110 of relay 2102 are internally connected with contacts that maybe connected by a contact bar in a similar manner as relay 18. When thecontact bar is closed, hard start capacitor replacement unit 2100 isconnected to the circuit. When the contact bar is open, hard startcapacitor replacement unit 2100 is disconnected from the circuit. Aribbon conductor 2126 connects the common cover terminal 2108 to, e.g.,the common element terminal. Conductors connect each of the capacitorcover terminals to their respective capacitive element terminals. Inanother implementation, the fuse 2104 could be elsewhere in the circuit.For example, the fuse 2104 could be electrically connecting theconductor 2106. In another implementation, the fuse could be included inthe conductor 2118 or associated with another conductor (e.g., theribbon conductor 2126).

In some arrangements, a fuse can also be used with a single value hardstart capacitor replacement unit rather than a hard start capacitorreplacement unit with multiple selectable values. For example, regardingFIG. 22, a single value hard start capacitor replacement unit 2200 isillustrated including an externally connected relay 2202 and a fuse 2204and is in use with a compressor motor and a motor run capacitor. Aconductor 2206 connects one cover terminal 2208 of the capacitor 2200 tothe external terminal 2210 (T-5) of the relay 2202. A conductor 2212connects a second cover terminal 2214 of the capacitor to an externalterminal 2216 (T-1) of the relay 2202. A bleeder resistor 2218 connectsthe external terminal 2216 of the potential relay 2202 to a secondexternal terminal 2210 of the relay 2202. A conductor 2220 includes thefuse 2204 and connects the external terminal 2210 to the compressormotor, the motor run capacitor, etc. Therefore, if the fuse 2204 opensan electrical connection due to a failure (e.g., a stuck relay, acompressor motor failure, a run capacitor failure, etc.), the hard startcapacitor replacement unit, the relay 2202, and the circuit aredisconnected, preventing damage to the compressor motor, other systemcomponents, etc. A conductor 2222 connects the external terminal 2224(T-2) of the relay 2202 to the compressor motor, the motor runcapacitor, etc. Referring back briefly to FIG. 4 and FIG. 9, theexternal terminals 2216, 2224, and 2210 of electronic relay 2202 areinternally connected with contacts and that may be closed by a contactbar in a similar manner as relay 18. When the contact bar is closed,hard start capacitor replacement unit 2200 is connected in parallel tothe compressor motor and the run capacitor. When the contact bar isopen, hard start capacitor 2200 and the circuit are disconnected. Inother implementations, the fuse could be connected elsewhere in thecircuit. For example, in another implementation, the fuse 2204 could beincluded in the conductor 2206. In another implementation, the fuse 2204can be included in the conductor 2210. In yet another implementation,the fuse 2204 can be included in the conductor 2220. In someimplementations, the fuse could be internal to the relay and integratedin the circuit of the relay (e.g., between an external terminal and therelay contacts). For example, the fuse can be included so that when thefuse opens an electrical connection, the contacts of the relay are nolonger electrically connected to the external terminals of the relay. Inanother implementation, the relay can be internal to the single valuehard start capacitor 2210.

In the implementations described above, the fuse is included in aconductor, so that when the fuse is intact, the conductor connects twocomponents of the system, but after the fuse opens an electricalconnection, the conductor no longer conducts electricity. Some examplesof a fuse included in a conductor are illustrated in FIGS. 23A and 23B.Referring to FIG. 23A, a conductor 2300 includes a fuse 2302 andconnections 2304. The fuse 2302 is included in the conductor 2300 sothat when the fuse 2302 is intact, the conductor 2300 conductselectricity, but after the fuse 2302 opens an electrical connection, theconductor 2300 does not conduct electricity. The connections 2304 are oneither end of the conductor 2300, and can connect the conductor 2300 todifferent electrical components (e.g., a relay, a start capacitor, acompressor motor, a run capacitor, etc.). The connections 2304 can alsoconnect to terminals of electrical components in different ways (e.g.,clamping, twisting around the terminals, etc.). In the illustratedexample, the sample type of connector is present on both ends of theconductor 2300; however, in other arrangements different types ofconnectors may be present at each end of the conductor. Referring toFIG. 23B, a conductor 2306 can include a fuse 2308 and connections 2310.The conductor 2306 can also include different indicia to indicateinformation about the fuse 2308, for example, a rating of the fuse. Forexample, the conductor 2306 may include, e.g., a black stripe 2312 toindicate that the fuse 2308 has a particular current rating (e.g., 10A),a particular type of fuse (e.g., a GSA(P) 10-R), etc. Similarly, theabsence of indicia can indicate information about the fuse (e.g.,absence of the black stripe indicates a lower current rating such as4A). Different ratings of fuses may be used depending on the wiring ofthe system and the amperage used by the start capacitor. For example,systems with greater capacitance require greater amperage. For example,in systems with jumper connections between capacitor terminals on a hardstart capacitor (e.g., wiring similar to FIG. 8), a fuse with a higherrating (e.g., 10A fuse) may be used. In systems without jumperconnections between terminals on a hard start capacitor (e.g., wiringsimilar to FIG. 5), a fuse with a lower rating (e.g., a 4 A fuse) may beused.

In some embodiments, the conductor 2300 with the fuse 2302 includesindicia to signify that it is related to safety and is a safety feature.In some embodiments, the conductor 2300 with the fuse 2302 can becolored a designated color (e.g., orange) to signify that it is a safetyfeature. For example, the designated color can signify that the fuse2302 removes equipment from the circuit in response to a failure (e.g.,a stuck relay, a capacitive failure, a motor failure, etc.). In someembodiments, the conductor 2300 can be colored the same designated coloras the booster terminal 1814, which also removes equipment from thecircuit in response to a failure, as described above. A common color forthe conductor 2300 and the booster terminal 1814 can designate to a userthat the conductor 2300 and the booster terminal 1814 have a commonpurpose of safety features. For example, the common color can help auser realize that multiple safety features (e.g., the conductor 2300,the booster terminal 1814, etc.) are being utilized in the circuit. Inother embodiments, the conductor 2300 and the booster terminal 1814 canbe different colors.

Although the hard start capacitors have been described as beingconnected to relays, multiple types of relays can be implemented (e.g.,potential relays, electronic relays, static relays, time delay relays,etc.). For example, although the figures may be described as using aparticular type of relay, other specific types of relay mayalternatively or additionally be used.

Although the external relays and fuses have been described as being usedwith dielectric hard start capacitors, the external relays and fuses canbe used with other types of hard start capacitors (e.g., electrolyticcapacitors).

Accordingly, a hard start capacitor replacement unit has been described.It will be appreciated that various changes may be made by those skilledin the art without departing from the spirit and scope of the invention,which is limited only by the following claims.

What is claimed is:
 1. A hard start capacitor replacement unit,comprising: a capacitor container having a cover; a plurality ofcapacitors received within the container, each of said capacitors havinga capacitance value; a common terminal mounted on the cover andelectrically connected to a common terminal of each of said plurality ofcapacitors; a plurality of cover terminals mounted on the cover spacedapart from the common terminal and from each other, each cover terminalrespectively electrically connected to one of the plurality ofcapacitors; a relay having contacts and being capable of opening andclosing said contacts in response to a monitored condition of the motor,the relay having relay terminals; a fuse electrically connected to oneof the relay terminals by a first wire wherein the fuse electricallydisconnects the hard start capacitor replacement unit and the motor upona failure; a second wire electrically connecting one of the relayterminals and the motor; a third wire electrically connecting the commonterminal and one of the relay terminals; and a fourth wire electricallyconnecting one or more cover terminals to one of the relay terminals;wherein the contacts of the relay close to electrically connect one ormore capacitors of the plurality of capacitors to the motor, and thecontacts of the relay open to electrically disconnect the one or morecapacitors of the plurality of capacitors from the motor.
 2. The hardstart capacitor replacement unit of claim 1, wherein the relay ispositioned external to the capacitor container.
 3. The hard startcapacitor replacement unit of claim 1, wherein the fuse electricallydisconnects the hard start capacitor replacement unit from the motorupon a current exceeding a threshold for a predetermined period of time.4. The hard start capacitor replacement unit of claim 3, wherein thethreshold is at least 4 amperes.
 5. The hard start capacitor replacementunit of claim 3, wherein the threshold is at least 10 amperes.
 6. Thehard start capacitor replacement unit of claim 3, wherein thepredetermined period of time is five seconds.
 7. The hard startcapacitor replacement unit of claim 1, wherein the fuse electricallydisconnects the hard start capacitor replacement unit from the motorupon a failure of the relay.
 8. The hard start capacitor replacementunit of claim 1, wherein the fuse electrically disconnects the hardstart capacitor from the motor upon a current exceeding 10 amperes for 5seconds.
 9. The hard start capacitor replacement unit of claim 1,wherein the fuse is electrically connected to a run capacitor of themotor.
 10. The hard start capacitor replacement unit of claim 9, whereinthe run capacitor includes a booster terminal.
 11. The hard startcapacitor replacement unit of claim 10, wherein the fuse electricallydisconnects the hard start capacitor and the booster terminal of the runcapacitor upon a failure.
 12. A hard start capacitor replacement unit,comprising: a capacitor container having a cover; a plurality ofcapacitors received within the container, each of said capacitors havinga capacitance value; a common terminal mounted on the cover andelectrically connected to a common terminal of each of said plurality ofcapacitors; a plurality of cover terminals mounted on the cover spacedapart from the common terminal and from each other, each cover terminalrespectively electrically connected to one of the plurality ofcapacitors; a relay having contacts and being capable of opening andclosing said contacts in response to a monitored condition of the motor,the relay having relay terminals; a fuse mounted to the relay andelectrically connected to the relay, wherein the fuse electricallydisconnects the hard start capacitor replacement unit and the motor upona failure; a first wire electrically connecting one of the relayterminals and the motor; a second wire electrically connecting thecommon terminal and one of the relay terminals; and a third wireelectrically connecting one or more capacitor cover terminals to one ofthe relay terminals; wherein the contacts of the relay close toelectrically connect one or more capacitors of the plurality ofcapacitors to the motor, and the contacts of the relay open toelectrically disconnect the one or more capacitors of the plurality ofcapacitors from the motor.
 13. The hard start capacitor replacement unitof claim 12, wherein the fuse electrically disconnects the hard startcapacitor from the motor upon a current exceeding a threshold for apredetermined period of time.
 14. The hard start capacitor replacementunit of claim 12, wherein the threshold is at least 4 amperes.
 15. Thehard start capacitor replacement unit of claim 12, wherein the thresholdis at least 10 amperes.
 16. The hard start capacitor replacement unit ofclaim 12, wherein the predetermined period of time is five seconds. 17.The hard start capacitor replacement unit of claim 12, wherein the fuseis mounted on an external surface of the relay.
 18. The hard startcapacitor replacement unit of claim 17, wherein the fuse is electricallyconnected to a relay terminal external to the relay.